ESTE MANUAL ES PARA LA NUEVA GENERACION DE SANY EN SURAMERICA...
www.sanygroup.com
Quailty Changes the World
Crawler Hydraulic Excavator
SY195C9 SY205C9 SY215C9
SANY HEAVY MACHINERY LIMITED
SY225C9
318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District, Shanghai, P.R. of China 201413
Tel: (86) 21 5700 8518 Service hotline:(86) 4006 098 318 E-mail:
[email protected] Documentation No.: ZJSYF0301EN(07-12)-SY55C3/55C9/60C1
Shop Manual
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Shop Manual
● Compiled for experienced technicians, this shop manual aims to provide technical information required for maintenance and repair of the machine. ● Work equipment or optional components not available locally may be included in this shop manual. Consult authorized Sany dealers for information on these parts and components. Material or technical specification is subject to change without prior notice.
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WARNING Read and follow the safety precautions and instructions in this manual and on the machine decals. Failure to do so may cause serious injury, death or property damage.
Table of Contents
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Table of Contents 1 Introduction
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1.1 How to Read the Shop Manual ................................................................................ 1-3 1.2 Terms for Maintenance Standard............................................................................. 1-5 1.3 Handling Electrical and Hydraulic Components....................................................... 1-7 1.3.1 Points to remember when handling electric components .............................. 1-7 1.3.2 Points to remember when handling hydraulic equipment ............................ 1-16 1.4 Hose Connector ..................................................................................................... 1-18 1.4.1 Type of hose connector................................................................................ 1-19 1.4.2 Hose connector tightening torque table ....................................................... 1-19 1.4.3 Connection of O-rings .................................................................................. 1-20 1.5 Table of Standard Tightening Torques .................................................................. 1-21 1.6 Type of Bolts .......................................................................................................... 1-22 1.7 Tightening Sequence ............................................................................................. 1-22 1.8 Maintenance of Half Flanges ................................................................................. 1-23 1.8.1 Table of tightening torques for half flange bolts ........................................... 1-23 1.9 Conversion Table ................................................................................................... 1-24
2 Shop Safety
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2.1 Hazard Alert Information .......................................................................................... 2-3 2.2 General Shop Safety ............................................................................................... 2-6 2.2.1 Rules and shop behavior ............................................................................... 2-7 2.2.2 Housekeeping ................................................................................................ 2-7 2.2.3 Shop Liquids Storage..................................................................................... 2-8 2.2.4 Cleaning Parts ............................................................................................... 2-8 2.2.5 Jacking Up the Machine................................................................................. 2-9 2.2.6 Electrical Dangers .......................................................................................... 2-9 2.2.7 Removing Attachments ................................................................................ 2-10 2.2.8 Cleaning the Machine .................................................................................. 2-10 2.2.9 Using the Correct Tools................................................................................ 2-10 2.2.10 Hoisting a Load ...........................................................................................2-11 2.2.11 Appropriate Working Apparel ..................................................................... 2-12 2.2.12 Safety Partners .......................................................................................... 2-12 2.2.13 Two people when engine running .............................................................. 2-13 2.2.14 Driving Pins ................................................................................................ 2-13 2.2.15 Aligning Parts or Components ................................................................... 2-14 Shop Manual - June 2013
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2.2.16 Fire Extinguisher and Emergency Exits ..................................................... 2-14 2.2.17 Personal Protective Equipment.................................................................. 2-14 2.2.18 Running the Machine ................................................................................. 2-15 2.2.19 Accumulator ............................................................................................... 2-16 2.2.20 Adding Fluids to a System ......................................................................... 2-16 2.2.21 Track Recoil Springs .................................................................................. 2-17 2.2.22 High-Pressure Fluid Lines.......................................................................... 2-17 2.2.23 Safe Work Preparations ............................................................................. 2-18 2.2.24 Mounting and Dismounting ........................................................................ 2-19 2.2.25 Battery Hazards ......................................................................................... 2-20 2.2.26 Jump-Start Safety ...................................................................................... 2-21 2.2.27 Disconnecting the System Power .............................................................. 2-21 2.2.28 Lockout/tagout ........................................................................................... 2-22 2.2.29 Sequence of Procedures ........................................................................... 2-22 2.2.30 Chemical hazard ........................................................................................ 2-24 2.2.31 Material Safety Data Sheets (MSDS) ........................................................ 2-24 2.3 Precautions for sling work and giving signals ........................................................ 2-25
3 Specifications
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Dimensions .............................................................................................................. 3-3 Working Ranges ...................................................................................................... 3-4 Technical Specifications........................................................................................... 3-5 Weight Table ............................................................................................................ 3-8 Recommended Oil, Fuel and Coolant...................................................................... 3-9 Capacity Table ....................................................................................................... 3-10 Engine Performance Curve ....................................................................................3-11
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3.1 3.2 3.3 3.4 3.5 3.6 3.7
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4 Structure and Function 4.1 Engine and Cooling System .................................................................................... 4-5 4.1.1 Engine-related parts....................................................................................... 4-5 4.1.2 Radiator and intercooler................................................................................. 4-6 4.2 Power Train.............................................................................................................. 4-7 4.2.1 Power transmission system .......................................................................... 4-7 4.2.2 Final drive assembly ...................................................................................... 4-8 4.2.3 Swing machinery...........................................................................................4-11 4.2.4 Swing bearing .............................................................................................. 4-13 4.3 Undercarriage and Frame...................................................................................... 4-14 4.3.1 Track frame and recoil spring....................................................................... 4-14 II
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4.3.2 Idler .............................................................................................................. 4-16 4.3.3 Carrier roller ................................................................................................. 4-18 4.3.4 Track roller ................................................................................................... 4-19 4.3.5 Track shoe ................................................................................................... 4-20 4.3.6 Triple grouser shoe ...................................................................................... 4-23 4.4 Hydraulic System, Part 1 ....................................................................................... 4-24 4.4.1 Hydraulic equipment layout.......................................................................... 4-24 4.4.2 Hydraulic tank and filter ............................................................................... 4-26 4.4.3 Hydraulic pump ................................................................................................... 4-27 4.4.4 Pilot pump .................................................................................................... 4-34 4.4.5 Regulator .................................................................................................... 4-35 4.4.5.1 Control mechanism makeup ............................................................... 4-37 4.4.5.2 Adjustment of the regulator ................................................................. 4-38 4.4.5.3 Operation ............................................................................................ 4-40 4.5 Hydraulic System, Part 2 ....................................................................................... 4-43 4.5.1 Control valve ................................................................................................ 4-43 4.5.2 Operating principle ....................................................................................... 4-46 4.5.2.1 When spool is in neutral position ........................................................ 4-46 4.5.2.2 Travel .................................................................................................. 4-48 4.5.2.3 Arm...................................................................................................... 4-49 4.5.2.4 Boom................................................................................................... 4-54 4.5.2.5 Bucket ................................................................................................. 4-57 4.5.2.6 Swing .................................................................................................. 4-59 4.5.2.7 Option ................................................................................................. 4-61 4.5.2.8 Travel straight ..................................................................................... 4-62 4.5.2.9 Lock valve function ............................................................................. 4-63 4.5.2.10 Main relief valve function .................................................................. 4-65 4.5.2.11 Port relief valve function .................................................................... 4-66 4.5.3 Section view ................................................................................................. 4-70 4.6 Hydraulic System, Part 3 ....................................................................................... 4-81 4.6.1 Swing motor ................................................................................................. 4-81 4.6.2 Swing holding brake..................................................................................... 4-83 4.6.3 Relief valve portion ...................................................................................... 4-84 4.6.4 Reverse prevention valve ............................................................................ 4-86 4.6.4.1 Operation drawing............................................................................... 4-86 4.6.4.2 Explanatory drawing of effects ............................................................ 4-87 4.6.5 Center swivel joint ........................................................................................ 4-89 4.6.6 Travel motor ................................................................................................. 4-91
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4.6.6.1 Operation of components.................................................................... 4-95 4.6.7 Valve control system .................................................................................. 4-107 4.6.8 Pilot valve.................................................................................................. 4-109 4.6.8.1 Work equipment and swing pilot valve.............................................. 4-109 4.6.8.2 Travel PPC valve ...............................................................................4-113 4.6.9 Solenoid valve.............................................................................................4-117 4.6.10 Accumulator ..............................................................................................4-118 4.6.11 Pilot oil filter ...............................................................................................4-119 4.6.12 Pump oil pressure sensor ........................................................................ 4-120 4.6.13 Hydraulic cylinder..................................................................................... 4-121 4.6.14 Work equipment ....................................................................................... 4-123 4.7 Air Conditioning System....................................................................................... 4-129 4.7.1 A/C components layout drawing ................................................................ 4-130 4.7.2 Control panel.............................................................................................. 4-131 4.7.3 Circuit diagram ........................................................................................... 4-132 4.7.4 Refrigeration principle ................................................................................ 4-134 4.7.4.1 Refrigeration cycle diagram .............................................................. 4-134 4.7.4.2 Heating cycle diagram ...................................................................... 4-134 4.7.5 Compressor ............................................................................................... 4-135 4.7.6 Clutch ......................................................................................................... 4-137 4.7.8 Condenser ................................................................................................. 4-138 4.7.7 Expansion valve ......................................................................................... 4-138 4.7.9 Evaporator ................................................................................................. 4-139 4.7.10 Receiver tank ........................................................................................... 4-139 4.7.11 Pressure switch ........................................................................................ 4-140 4.7.12 Fresh air sensor ....................................................................................... 4-141 4.7.13 Refrigerant ............................................................................................... 4-141 4.7.14 Compressor oil ......................................................................................... 4-160 4.8 Engine Control ..................................................................................................... 4-161 4.8.1 System operation ...................................................................................... 4-162 4.8.2 Components............................................................................................... 4-163 4.8.2.1 Fuel control dial................................................................................. 4-163 4.8.2.2 Controller .......................................................................................... 4-165 4.9 Electrical Control System..................................................................................... 4-167 4.9.1 Control function .......................................................................................... 4-167 4.9.2 Machine control system diagram ............................................................... 4-168 4.9.3 Engine and pump composite control function ............................................ 4-170 4.9.4 Pump control function ................................................................................ 4-174
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4.9.4.1 Electrical positive flow control ........................................................... 4-175 4.9.4.2 Constant power control ..................................................................... 4-178 4.9.5 Valve control function ................................................................................. 4-180 4.9.5.1 Bucket flow control ............................................................................ 4-181 4.9.5.2 Swing priority control......................................................................... 4-182 4.9.6 Duo travel speed control ............................................................................ 4-183 4.9.7 Engine preheating/overheating alarm ....................................................... 4-185 4.9.7.1 Engine preheating ............................................................................. 4-186 4.9.7.2 Engine overheating alarm ................................................................. 4-187 4.9.8 Engine oil under–pressure alarm ............................................................... 4-187 4.9.9 Auto deceleration/acceleration control ....................................................... 4-188 4.9.10 Engine speed calibration function ............................................................ 4-190 4.9.11 Electrical Components ............................................................................. 4-192 4.9.11.1 Pump pressure sensor .................................................................... 4-192 4.9.11.2 Pilot pressure sensor ...................................................................... 4-193 4.9.11.3 Engine speed sensor ...................................................................... 4-194 4.9.11.4 Coolant temperature sensor............................................................ 4-195 4.9.11.5 Fuel level sensor ............................................................................. 4-196 4.9.11.6 Oil pressure switch .......................................................................... 4-197 4.10 Monitoring System ............................................................................................. 4-198 4.10.1 Machine monitor ...................................................................................... 4-199 4.10.2 Monitor functions...................................................................................... 4-200 4.10.3 Monitor operation ..................................................................................... 4-203
5 Standard Values
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5.1 Standard Values of Engine - related Parts............................................................... 5-3 5.2 Standard Values of Chassis-related Parts ............................................................... 5-4
6 Testing and Adjusting 6.1 Engine Speed - Test and Calibrate .......................................................................... 6-3 6.1.1 Testing ........................................................................................................... 6-3 6.1.2 Adjusting ........................................................................................................ 6-3 6.2 Exhaust Gas Color - Test ......................................................................................... 6-6 6.3 Valve Clearance - Adjust.......................................................................................... 6-8 6.3.1 Testing............................................................................................................ 6-8 6.3.2 Adjusting ...................................................................................................... 6-10 6.4 Compression Pressure - Measure ..........................................................................6-11 6.5 Fuel Injection Timing - Test and Adjust .................................................................. 6-13 Shop Manual - June 2013
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6.5.1 Testing.......................................................................................................... 6-13 6.5.2 Adjusting ...................................................................................................... 6-15 6.6 Engine Oil Pressure - Measure.............................................................................. 6-17 6.7 Engine Speed Sensor - Adjust ............................................................................... 6-19 6.8 A/C Compressor Belt Tension - Test and Adjust ................................................... 6-20 6.8.1 Testing ......................................................................................................... 6-20 6.8.2 Adjusting ...................................................................................................... 6-20 6.9 Swing Bearing Clearance - Measure ..................................................................... 6-22 6.10 Track Tension - Test and Adjust ........................................................................... 6-24 6.10.1 Testing........................................................................................................ 6-24 6.10.2 Adjusting .................................................................................................... 6-25 6.11 Hydraulic Pressure in Hydraulic Circuits - Test and Adjust .................................. 6-26 6.11.1 Measuring .................................................................................................. 6-26 6.11.2 Adjusting..................................................................................................... 6-28 6.12 Control Circuit Oil Pressure - Test and Adjust...................................................... 6-30 6.12.1 Testing........................................................................................................ 6-30 6.12.2 Adjusting .................................................................................................... 6-31 6.13 Solenoid Valve Output Pressure - Measure......................................................... 6-32 6.14 Pilot Valve Output Pressure - Measure................................................................ 6-34 6.15 Pilot Valves (Work Equipment and Swing) - Adjust ............................................. 6-36 6.16 Work Equipment Hydraulic Drift - Test ................................................................. 6-37 6.17 Residual Pressure in Hydraulic Circuit - Release ................................................ 6-40 6.18 Oil Leakage - Measure ........................................................................................ 6-41 6.19 Air in Each Component - Bleed............................................................................ 6-46
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7 Troubleshooting
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7.1 Points to Remember When Troubleshooting ........................................................... 7-3 7.2 Troubleshooting Procedures .................................................................................... 7-5 7.3 Connector Location and Electrical Circuit Diagram ................................................. 7-8 7.3.1 Connector location layout ............................................................................ 7-12 7.3.2 Electrical element circuit diagram (cab circuit)............................................. 7-18 7.3.3 Electrical control circuit diagram (engine circuit).......................................... 7-20 7.3.4 Electrical control circuit diagram (sensor and solenoid valve circuit) ........... 7-22 7.3.5 SWP type connector .................................................................................... 7-23 7.3.6 A/AMP type connector ................................................................................. 7-24 7.3.7 DT type connector ....................................................................................... 7-25 7.4 Failure Symptoms and Troubleshooting Codes ..................................................... 7-26 7.5 Troubleshooting with an Event Code ..................................................................... 7-28 VI
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7.6 Troubleshooting of Electrical System (E - Mode)................................................... 7-63 7.7 Troubleshooting of Hydraulic and Mechanical Systems (H - Mode) ...................... 7-93
8 Disassembly and Assembly
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8.1 How to Read This Manual ....................................................................................... 8-5 8.1.1 Removing and Installing an Assembly ........................................................... 8-5 8.1.2 Disassembling and assembling an assembly ................................................ 8-5 8.1.3 Special tools................................................................................................... 8-5 8.2.1 The symbols used in this section .................................................................. 8-6 8.2 Operating Precautions ............................................................................................. 8-6 8.3 Start Motor AS - Remove and Install ..................................................................... 8-10 8.3.1 Removal ....................................................................................................... 8-10 8.3.2 Installation .................................................................................................... 8-10 8.4 Injection Pump AS - Remove and Install ................................................................8-11 8.4.1 Removal ........................................................................................................8-11 8.4.2 Installation .................................................................................................... 8-13 8.5 Engine Front Seal - Remove and Install ................................................................ 8-15 8.5.1 Removal ....................................................................................................... 8-15 8.5.2 Installation .................................................................................................... 8-15 8.6 Engine Rear Seal - Remove and Install................................................................. 8-16 8.6.1 Removal ....................................................................................................... 8-16 8.6.2 Installation .................................................................................................... 8-17 8.7 Cylinder Head AS - Remove and Install ................................................................ 8-18 8.7.1 Removal ....................................................................................................... 8-18 8.7.2 Installation .................................................................................................... 8-22 8.8 Radiator AS - Remove and Install.......................................................................... 8-24 8.8.1 Removal ....................................................................................................... 8-24 8.8.2 Installation .................................................................................................... 8-27 8.9 Engine and Hydraulic Pump AS - Remove and Install .......................................... 8-28 8.9.1 Removal ....................................................................................................... 8-28 8.9.2 Installation .................................................................................................... 8-34 8.10 Final Drive AS - Remove and Install .................................................................... 8-35 8.10.1 Removal ..................................................................................................... 8-35 8.10.2 Installation .................................................................................................. 8-36 8.11 Final Drive AS - Disassemble and Assemble ....................................................... 8-37 8.11.1 Disassembly ............................................................................................... 8-37 8.11.2 Assembly .................................................................................................... 8-41 8.12 Swing Motor and Swing Drive AS - Remove and Install ...................................... 8-46 Shop Manual - June 2013
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8.12.1 Removal ..................................................................................................... 8-46 8.12.2 Installation .................................................................................................. 8-47 8.13 Swing Motor and Swing Drive AS - Disassemble and Assemble......................... 8-48 8.13.1 Disassembly............................................................................................... 8-48 8.13.2 Assembly.................................................................................................... 8-53 8.14 Idler AS - Disassemble and Assemble ................................................................. 8-58 8.14.1 Disassembly............................................................................................... 8-58 8.14.2 Assembly.................................................................................................... 8-59 8.15 Sprocket - Remove and Install............................................................................. 8-62 8.15.1 Removal ..................................................................................................... 8-62 8.15.2 Installation .................................................................................................. 8-62 8.16 Track AS - Remove and Install ............................................................................ 8-63 8.16.1 Removal ..................................................................................................... 8-63 8.16.2 Installation .................................................................................................. 8-65 8.17 Swing Bearing AS - Remove and Install .............................................................. 8-66 8.17.1 Removal ..................................................................................................... 8-66 8.17.2 Installation .................................................................................................. 8-67 8.18 Swing Platform AS - Remove and Install ............................................................. 8-68 8.18.1 Removal ..................................................................................................... 8-68 8.18.2 Installation .................................................................................................. 8-71 8.19 Swivel Joint AS - Remove and Install .................................................................. 8-72 8.19.1 Removal ..................................................................................................... 8-72 8.19.2 Installation .................................................................................................. 8-74 8.20 Swivel Joint AS - Disassemble and Assemble ..................................................... 8-75 8.20.1 Disassembly............................................................................................... 8-75 8.20.2 Assembly.................................................................................................... 8-76 8.21 Hydraulic Tank AS - Remove and Install.............................................................. 8-77 8.21.1 Removal ..................................................................................................... 8-77 8.21.2 Installation .................................................................................................. 8-79 8.22 Control Valve AS - Remove and Install ................................................................ 8-80 8.22.1 Removal ..................................................................................................... 8-80 8.22.2 Installation .................................................................................................. 8-84 8.23 Hydraulic Pump AS - Remove and Install ............................................................ 8-85 8.23.1 Removal ..................................................................................................... 8-85 8.23.2 Installation .................................................................................................. 8-89 8.24 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install .................... 8-90 8.24.1 Removal ..................................................................................................... 8-90 8.24.2 Installation .................................................................................................. 8-90
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8.25 Pilot Valve AS (Work Equipment) - Disassemble and Assemble ......................... 8-91 8.25.1 Assembly.................................................................................................... 8-91 8.26 Pilot Valve AS (Travel) - Disassemble and Assemble .......................................... 8-93 8.26.1 Assembly.................................................................................................... 8-93 8.27 Hydraulic Cylinder AS - Disassemble and Assemble........................................... 8-94 8.27.1 Disassembly............................................................................................... 8-95 8.27.2 Assembly.................................................................................................. 8-100 8.28 Work Equipment AS - Remove and Install......................................................... 8-105 8.28.1 Removal ................................................................................................... 8-105 8.28.2 Installation ................................................................................................ 8-107 8.29 Air Conditioner AS - Remove and Install............................................................ 8-108 8.29.1 Removal ................................................................................................... 8-108 8.29.2 Installation .................................................................................................8-112 8.30 Counterweight AS - Remove and Install .............................................................8-113 8.30.1 Removal ....................................................................................................8-113 8.30.2 Installation .................................................................................................8-114 8.31 Cab AS - Remove and Install..............................................................................8-115 8.31.1 Removal ....................................................................................................8-115 8.31.2 Installation .................................................................................................8-119 8.32 Cab Window Glass – Disassemble and Assemble ............................................ 8-120 8.32.1 Removal ................................................................................................... 8-121 8.32.2 Installation ................................................................................................ 8-125 8.33 Front Window AS - Disassemble and Assemble................................................ 8-138 8.33.1 Disassemble ............................................................................................ 8-138 8.33.2 Assemble ................................................................................................. 8-141 8.34 Monitor - Remove and Install ............................................................................. 8-146 8.34.1 Removal ................................................................................................... 8-146 8.34.2 Installation ................................................................................................ 8-146 8.35 Controller AS - Remove and Install.................................................................... 8-147 8.35.1 Removal ................................................................................................... 8-147 8.35.2 Installation ................................................................................................ 8-147 8.36 Radio ................................................................................................................. 8-148 8.36.1 Structure .................................................................................................. 8-148 8.36.2 Removal ................................................................................................... 8-149 8.36.3 Installation ................................................................................................ 8-150 8.36.4 Connector model and wiring .................................................................... 8-150 8.37 Battery ............................................................................................................... 8-151 8.37.1 Structure .................................................................................................. 8-151
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8.37.2 Removal ................................................................................................... 8-152 8.37.3 Installation ................................................................................................ 8-153 8.37.4 Replacement ............................................................................................ 8-153 8.38 Start Switch........................................................................................................ 8-154 8.38.1 Structure ................................................................................................. 8-154 8.38.2 Removal ................................................................................................... 8-155 8.39 Fuse Box............................................................................................................ 8-157 8.39.1 Removal ................................................................................................... 8-157 8.40 Wiper ................................................................................................................. 8-158 8.40.1 Structure .................................................................................................. 8-158 8.40.2 Working principle ..................................................................................... 8-158 8.40.3 Removal ................................................................................................... 8-159 8.40.5 Installation ................................................................................................ 8-160 8.40.4 Angle adjustment of wiper arm................................................................. 8-160 8.41 Relay.................................................................................................................. 8-161 8.41.1 Engine relays ........................................................................................... 8-161 8.41.2 Other relays ............................................................................................. 8-162 8.42 Sensor ............................................................................................................... 8-165 8.43 Connector Terminals - Insert and Remove ........................................................ 8-167 8.43.1 Insertion ................................................................................................... 8-167 8.43.2 Removal ................................................................................................... 8-168
9 System Schematics
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Hydraulic System Diagram ...................................................................................... 9-3 Air-Conditioning Electrical Circuit Diagram .............................................................. 9-4 Fuse Box Relay ....................................................................................................... 9-5 Control Switches and Monitor Electrical Diagram ................................................... 9-6 Operator Cab Electrical Circuit Diagram.................................................................. 9-7 Chassis Electrical Circuit Diagram........................................................................... 9-8
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Introduction
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1 Introduction
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1.1 How to Read the Shop Manual ................................................................................ 1-3 1.2 Terms for Maintenance Standard............................................................................. 1-5 1.3 Handling Electrical and Hydraulic Components....................................................... 1-7 1.3.1 Points to remember when handling electric components .............................. 1-7 1.3.2 Points to remember when handling hydraulic equipment ............................ 1-16 1.4 Hose Connector ..................................................................................................... 1-18 1.4.1 Type of hose connector................................................................................ 1-19 1.4.2 Hose connector tightening torque table ....................................................... 1-19 1.4.3 Connection of O-rings .................................................................................. 1-20 1.5 Table of Standard Tightening Torques .................................................................. 1-21 1.6 Type of Bolts .......................................................................................................... 1-22 1.7 Tightening Sequence ............................................................................................. 1-22 1.8 Maintenance of Half Flanges ................................................................................. 1-23 1.8.1 Table of tightening torques for half flange bolts ........................................... 1-23 1.9 Conversion Table ................................................................................................... 1-24
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SY195/205/215/225C9 Crawler Hydraulic Excavator
1-2
WARNING
Read and understand all safety precautions and instructions in this manual before reading any other manuals provided with this machine and before operating or servicing the machine. Also read the safety information on machine decals before performing any operations. Failure to do so can cause machine damage, personal injury or death.
Shop Manual - June 2013
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
1 INTRODUCTION 1.1 How to Read the Shop Manual 1. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
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Introduction
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This section provides an overview of what is covered in the rest of this manual and how to use this manual,. Shop Safety
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This section covers basic shop safety information relating to this equipment. It also describes what the hazard alerts mean that are used throughout the manual. Specifications
Technical specification of work equipment and optional parts are given in this section.
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Structure and function
Standard Values
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This section explains the structure and function of each component. It helps the reader to get a better understanding of the machine structure, and also serves as a reference for troubleshooting.
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This section explains the standard values for a new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. Testing and adjusting
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This section details the inspection before and after repair work as well as the adjustment during inspection and repair work. Troubleshooting table that involves “Fault”and “Cause”are also included in this section. Troubleshooting This section explains the way to detect faulty parts and the method to repair them. This section is divided into the following parts: Electrical system, Engine, Hydraulic and mechanical system and Monitoring system. Disassembly and assembly This section explains the procedures as well as precautions for removing, installing, disassembling and assembling of each component.
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Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
System Schematics This section provides hydraulic circuit diagrams and electrical circuit diagrams. 2. Revision and distribution
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Any additions, revisions, or other change of notices will be sent to Sany distributors. Get the most up-to-date information before you start any work.
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3. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
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4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Item
Remarks
Safety
Special technical precautions or other precautions for preserving standards are necessary when performing work.
Weight
Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
Tightening torque
Places that require special attention for tightening torque during assembly.
Coat
Places to be coated with adhesives, etc. during assembly.
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Oil, Coolant Drain
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Special safety precautions are necessary when performing work.
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Symbol
Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.
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Introduction
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1.2 Terms for Maintenance Standard The maintenance standard values necessary for judgment of products and parts are described by the following terms. 1. Standard size and tolerance
RI C
A
● To be accurate, the finishing size of parts is a little different from one to another.
● The above size set temporarily is called the "standard size" and the range of difference from the standard size is called the "tolerance".
TI N
● The tolerance with the symbols of + or – is indicated on the right side of the standard size.
120
Tolerance
LA
Example Standard size
AM E
● To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated.
–0.022 –0.126
SA
NY
NOTE: The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126) ● Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance.
Std.size F 60 Tolerance of hole (upper):+0.046 Std.clearance (max.):0.122 Std.clearance (min.):0.030 Tolerance of shaft (lower):-0.076 Tolerance of shaft (upper):-0.030
● Indication of size of rotating shaft and hole and relationship drawing of them. ZX215-1000003
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1-5
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
4. Repair limit and allowable value
φ60
Hole +0.046 0
2. Standard clearance and standard value ● The clearance made when new parts are assembled is called the "standard clearance", which is indicated by the range from the minimum clearance to the maximum clearance. ● When some parts are repaired, the clearance is generally adjusted to the standard clearance.
● The performance and function of a product lowers while it is used. A value below which the product can be used without causing a problem is called the "allowable value". ● If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement. 5. Clearance limit
TI N
● A value of performance and function of new products or equivalent is called the "standard value", which is indicated by a range or a target value.
● If a part is worn to the repair limit must be replaced or repaired.
A
Shaft -0.030 -0.076
● The size of a part changes due to wear and deformation while it is used. The limit of changed size is called the "repair limit".
RI C
Tolerance
Standard size
AM E
Example
3. Standard interference
LA
● When some parts are repaired, the value of performance/function is set to the standard value.
NY
● When the size of a hole is smaller than the size of a shaft because of the standard size and tolerance, the difference between these sizes is called the "interference".
SA
● The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the shaft to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the "standard interference". ● After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.
1-6
● Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the "clearance limit". ● If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired.
6. Interference limit ● The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the "interference limit". ● The interference limit shows the repair limit of the part of smaller tolerance. ● If the interference between the parts exceeds the interference limit, they must be replaced or repaired.
Shop Manual - June 2013
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
1.3 Handling Electrical and Hydraulic Components
AM E
RI C
A
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on "Handling electric components" and "Handling hydraulic equipment" (particularly gear oil and hydraulic oil).
1.3.1 Points to remember when handling electric components 1. Handling wiring harnesses and connectors
LA
TI N
Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring.
ZX215-1000004
SA
NY
Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses.
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1-7
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
2. Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Improper insertion
RI C
A
Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidation of the contact surfaces.
2) Defective crimping or soldering of connectors
3) Disconnections in wiring
LA
TI N
The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
AM E
ZX215-1000005
Crimped portion
ZX215-1000006
SA
NY
If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
ZX215-1000007
1-8
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Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
RI C
ZX215-1000008
AM E
The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be shortcircuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.
A
4) High-pressure water entering connector
TI N
5) Oil or dirt stuck to connector
NOTE:
NY
LA
If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer.
ZX215-1000009
SA
● When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. ● If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
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1-9
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
3. Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors a. Hold the connectors when disconnecting.
b. When removing from clips
A ZX215-1000010
Both stoppers
ZX215-1000011
NY
LA
TI N
● Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
RI C
NOTE: Never pull with one hand.
Lock stopper
AM E
When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart.
Press lightly when removing
SA
● When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers.
ZX215-1000012
1-10
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Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
c. Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion.
RI C
A
NOTE: If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
a. Check the connector visually Check that there is no oil, dirt, or water stuck to the connector pins (mating portion).
AM E
2) Connecting connectors
ZX215-1000013
Clicks into position
TI N
Check that there is no deformation, defective contact, corrosion, or damage to the connector pins.
ZX215-1000022
LA
Check that there is no damage or breakage to the outside of the connector.
SA
NY
NOTE: If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. NOTE: If there is any damage or breakage, replace the connector.
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Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
b. Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position.
A
c. Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
RI C
ZX215-1000014
AM E
NOTE: If the connector cannot be corrected easily, remove the clamp and adjust the position.
LA
TI N
● If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
ZX215-1000015
3) Connecting DT connectors
2
a
1
c
NY
Since the DT 8-pin and 12-pin heavy duty wire connectors have 2 latches respectively, push them in until they click 2 times.
SA
● Male connector: 1
● Female connector: 2 ● Normal locking state (Horizontal): a, b, d
b
d ZX215-1000016
● Incomplete locking state (Diagonal): c
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Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
4) Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows.
b. Dry the connector with a dryer.
RI C
ZX215-1000009
AM E
NOTE: If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.
A
a. Disconnect the connector and wipe off the water with a dry cloth.
TI N
If water gets inside the connector, use a dryer to dry the connector.
ZX215-1000017
LA
NOTE: Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
NY
c. Carry out a continuity test on the connector.
SA
After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. NOTE: After completely drying the connector, blow it with contact restorer and reassemble.
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T adapter
ZX215-1000018
1-13
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
4. Handling the integrated control monitor
A
1) The controller contains a microcomputer and an electronic control circuits. They control all of the electronic circuits on the machine, so be extremely careful when handling the integrated control monitor.
RI C
2) Do not place objects on the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand.
6) Precautions for arc welding
TI N
5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time.
AM E
4) Do not leave it where it may be exposed to rain.
ZX215-1000019
ZX215-1000020
SA
NY
LA
When welding on the controller, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
Tool Box
ZX215-1000021
1-14
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Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
5. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
RI C
A
NOTE: Disconnect and connect the related connectors several times to check.
NOTE: If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated.
TI N
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester.
AM E
3) Always connect any disconnected connectors before going on to the next step.
SA
NY
LA
NOTE: If there is any change, there is probably defective contact in that circuit.
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Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
1.3.2 Points to remember when handling hydraulic equipment
RI C
A
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. 2. Disassembly and maintenance work in the field
ZX215-1000023
NY
LA
TI N
If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dust-proof workshop, and the performance should be checked with special test equipment.
AM E
1. Be careful of the operating environment
SA
3. Sealing openings
After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.
1-16
Shop Manual - June 2013
ZX215-1000024
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
4. Do not let any dirt or dust get in during refilling operations
RI C
A
Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
LA
TI N
When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.
ZX215-1000025
AM E
5. Change hydraulic oil when the temperature is high
NY
6. Flushing operations
Flushing oil
SA
After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
ZX215-1000026
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Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
7. Cleaning operations
A
After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 μ) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.
1.4 Hose Connector
TI N
Hose connector is used to connect hoses with a small diameter. The metal sealing surface (4) of the joint (1) must be in close contact with the metal sealing surface (5) of the hose (2) to seal pressurized oil.
AM E
RI C
ZX215-1000027
NOTICE
NY
LA
● Do not over-tighten the nut (3). Excessive force applied on the metal sealing surface (4) and (5) may cause the joint (1) to break. Be sure to tighten nut (3) according to technical specifications.
SA
● Scratches or other damages on sealing surface (4) and (5) may cause leaks at the joint. Be extremely careful not to damage the sealing surfaces during connecting and disconnecting work.
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1
4
3
5
2
Connector ZX215-1000028
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
1.4.1 Type of hose connector 24° 24°
Female
A
Male
RI C
ZX215-1000029
Type
Wrench size mm
Wrench size mm
Connecting nut
AM E
1.4.2 Hose connector tightening torque table
Hose joint
N·m(kgf·m,Ibf·ft)
19
59(6,44)
22
98(10,72)
27
118(12,87)
36
235(24,173)
41
41
295(30,218)
50
50
490(50,361)
60
60
670(68,494)
70
70
980(100,723)
19
17
44(4.5,32)
22
19
59(6,44)
27
22
118(12,87)
36
30, 32
235(24,173)
41
36
295(30,218)
50
46
490(50,361)
19 22 27 36
LA
TI N
24° Male
SA
NY
24° Female
Tightening torque
NOTICE
● The torque values listed in the table are intended for general application. ● Do not use torque values listed in this table when different torque values are specified for a special purpose.
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Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
1.4.3 Connection of O-rings Place O-ring (6) in contact with the contact surface of the joint (7) to seal the pressurized oil.
7
6
9
NOTICE
A
● Replace o-rings (6) with new ones when re-connecting hoses.
Hose connector
RI C 8
● Before tightening nut (9), make sure the o-ring (6) has been placed into the o-ring seat (8).Displacement of the o-ring may have it damaged and cause leaks.
10
AM E
ZX215-1000030
● Be careful not to damage the o-ring seat (8) or the sealing surface (10). Damaged o-ring (6) may cause oil leakage.
Wrench size mm
LA
TI N
● If oil leakage due to loosened nut (9) is detected, do not try to stop the leakage by tightening nut (9). Instead, replace oring (6) with a new one and make sure it is well positioned, and tighten nut (9).
Wrench size mm
Tightening torque
Hose joint
N·m (kgf·m,Ibf·ft)
19
17
44(4.5,32)
22
19
59(6,44)
27
22
118(12,87)
36
30, 32
235(24,173)
41
36
295(30,218)
50
46
490(50,361)
SA
NY
Connecting nut
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Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
1.5 Table of Standard Tightening Torques Table of tightening torques for bolts and nuts ● Unless specified otherwise, tighten metric nuts and bolts to the torque below. (When using torque wrench)
Bolt diameter
Bolt grade
Wrench Hex wrench size size
M6
10.9
10
M8
10.9
M10
Hexagonal bolt
Hexagonal socket head bolt
kgf·m
lbf·ft
N·m
4
13.2
1.37
9.74
13.2
13
6
31
3.16
22.87
31
3.16
22.87
10.9
17
8
66
6.73
48.7
66
6.73
48.7
M12
10.9
19
10
113
11.53
83.39
113
11.53
83.39
M14
10.9
22
12
177
18.06
130.6
177
18.06
130.6
M16
10.9
24
14
279
28.47
205.9
279
28.47
205.9
M18
10.9
27
14
382
38.98
281.9
382
38.98
281.9
M20
10.9
30
17
549
56.02
405.16
549
56.02
405.16
M27
10.9
41
19
1320
134.7
974.16
1320
134.7
974.16
M10
12.9
17
6
78
7.96
57.76
78
7.96
57.76
M12
12.9
19
8
137
13.98
101.1
137
13.98
101.1
M16
12.9
24
14
339
34.6
250.18
339
34.6
250.18
M20
12.9
30
17
664
67.75
490
664
67.75
490
lbf·ft
1.37
9.74
RI C
AM E
TI N
LA
kgf·m
A
N·m
NOTICE
The following items apply to fine thread and coarse thread.
NY
● Apply grease (zinc white B dissolved in spindle oil) onto the nuts and bolts to reduce the friction coefficient. Thrust bolts do not require greasing.
SA
● Torque tolerance is ±10%. ● Always use bolts of correct length. The tip of bolts with excessive length may contact the bottom of the bolt hole, resulting in under-tightening. Bolts with inadequate length may result in insufficient fastening. ● The torque values listed in the table are intended for general application. If different torque values are specified for a special purpose, the torque values in this table are not applicable any more. ● Make sure the threads are free of dirt or rusts before installation of nuts and bolts.
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Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
1.6 Type of Bolts Tighten nuts and bolts properly to specified torque values. The type and grade of bolts are illustrated on the right. Hex bolt
Use correct bolts and tighten them properly when assembling machines or components.
12.9
10.9
RI C
A
8.8
Socket head hex bolt
ZX215-1000031
When two or more bolts are being tightened, follow the tightening sequence shown on the right to ensure even tightening.
AM E
1.7 Tightening Sequence
Cross tightening
Diagonal tightening 1
1
3
3
6
4
5
4
CAUTION
TI N
2
● Always use suitable tools for specific work. Use of improper tools and methods may cause a hazardous situation.
Central and diagonal tightening 12
9
4
1
6
7
14
13
8
5
2
3
10
11
ZX215-1000032
SA
NY
LA
● Use tools of correct sizes when loosening or tightening the nuts or bolts. Otherwise, the tools may slide and cause personal injury.
2
ZX215-1000033
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SY195/205/215/225C9 Crawler Hydraulic Excavator
1.8 Maintenance of Half Flanges
A
1. Clean the sealing surface of the flange and check it carefully. Scratches and coarseness cause leaks or abrasion of seals. Uneven surface may squeeze the seal out. If these faults are not corrected properly, parts may have to be replaced.
AM E
ZX215-1000034
Improper
LA
TI N
3. Tighten the half flanges carefully. Locate the opening at the center so that it is perpendicular to the oil opening. Tighten the bolt manually to maintain the location of the components.
RI C
2. Always use specified O-rings. Check that the O-rings are not damaged. Do not file the surface of the O-ring. Apply grease onto the O-ring to locate it.
ZX215-1000035
1.8.1 Table of tightening torques for half flange bolts
NY
● Unless specified otherwise, tighten the half flange bolts to the torques below.
SA
Thread diameter of bolt
Width across flats
Tightening torque
mm
mm
Nm
kgm
10 12 16
14 17 22
59~74 98~123 235~285
6.0~7.5 10.0~12.5 23.5~29.5
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Introduction
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1.9 Conversion Table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches 1. Convert 55 mm into inches
RI C
A
1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B).
AM E
3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches
1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm.
TI N
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
SA
NY
LA
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
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Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
Length Millimeters to Inches 1mm=0.03937in
(B) 2
3
4
5
6
7
8
9
0 10 20 30 40
0.000 0.394 0.787 1.181 1.575
0.039 0.433 0.827 1.220 1.614
0.079 0.472 0.866 1.260 1.654
0.118 0.512 0.906 1.299 1.693
0.157 0.551 0.945 1.339 1.732
0.197 0.591 0.984 1.378 1.772 (C)
0.236 0.630 1.024 1.417 1.811
0.276 0.669 1.063 1.457 1.850
0.315 0.709 1.102 1.496 1.890
0.354 0.748 1.142 1.535 1.929
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.031 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
1
2
0 10 20 30 40
0 0.394 0.787 1.181 1.575
0.039 0.433 0.827 1.220 1.614
0.079 0.472 0.866 1.260 1.654
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
NY
SA
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
RI C
1mm=0.03937in
3
4
5
6
7
8
9
0.118 0.512 0.906 1.299 1.693
0.157 0.551 0.945 1.339 1.732
0.197 0.591 0.984 1.378 1.772
0.236 0.630 1.024 1.417 1.811
0.276 0.669 1.063 1.457 1.850
0.315 0.709 1.102 1.496 1.890
0.354 0.748 1.142 1.535 1.929
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.031 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
LA
0
TI N
Millimeters to Inches
A
1
AM E
(A)
0
Shop Manual - June 2013
1-25
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
Inches to Millimeters mm
1/32 1/16 3/32 1/8
19/32
3.5719
3/16
4.3656 4.7625
13/64
41/64
5.5563 15/64
1/4 9/32
23/64
9.1281
13/32
10.3188
25/64 27/64
7/16
9.5250
15/32
51/64
7/8 29/32
19.4469 20.2406 21.0344 21.8281 22.6219 23.0188
59/64 15/16
23.4156 23.8125
11.5094
61/64 31/32
24.2094 24.6063
63/64
Shop Manual - June 2013
18.6531
22.2250 57/64
1
17.8594
21.4313 55/64
10.7156
12.7000
17.0656
20.6375 27/32
12.3031
16.6688
19.8438
53/64
11.9063 31/64
25/32
9.9219
11.1125 29/64
49/64
13/16
8.7313
16.2719
19.0500
8.3344
NY
11/32
15.8750
18.2563
3/4
7.5406
LA
21/64
45/64 47/64
6.7469
7.9375
15.4781
17.4625
23/32
7.1438
19/64
43/64
11/16
5.9531
6.3500
17/64
21/32
TI N
7/32
5.1594
14.6844 15.0813
39/64
3.9688 11/64
SA
37/64
5/8
13.8906 14.2875
AM E
5/32
1-26
9/16
2.7781
13.0969 13.4938
35/64
1.9844
3.1750 9/64
1/2
17/32
2.3813 7/64
5/16
33/64
1.1906 1.5875
5/64
3/8
0.3969 0.7938
3/64
mm
A
1/64
in.
RI C
in.
25.0031 25.4000
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
Feet to Meters 0
1
2
3
4
5
6
7
8
9
ft.
m
m
m
m
m
m
m
m
m
m
-
-
0.305
0.610
0.914
1.219
1.524
1.829
2.134
2.438
2.743
-
10
3.048
3.353
3.658
3.962
4.267
4.572
4.877
5.182
5.486
5.791
10
20
6.096
6.401
6.706
7.010
7.315
7.620
7.925
8.230
8.534
8.839
20
30
9.144
9.449
9.754
10.058 10.363 10.668 10.973 11.278 11.582 11.887
30
40
12.192 12.497 12.802 13.106 13.411 13.716 14.021 14.326 14.630 14.935
50
15.240 15.545 15.850 16.154 16.459 16.764 17.069 17.374 17.678 17.983
50
60
18.288 18.593 18.898 19.202 19.507 19.812 20.117 20.422 20.726 21.031
60
70
21.336 21.641 21.946 22.250 22.555 22.860 23.165 23.470 23.774 24.079
70
80
24.384 24.689 24.994 25.298 25.603 25.908 26.213 26.518 26.822 27.127
80
90
27.432 27.737 28.042 28.346 28.651 28.956 29.261 29.566 29.870 30.175
90
100
30.480 30.785 31.090 31.394 31.699 32.004 32.309 32.614 32.918 33.223
100
AM E
RI C
A
ft.
40
m
1
2
ft.
ft.
ft.
-
3.2808
6.5617
3
4
5
6
7
8
9
ft.
ft.
ft.
ft.
ft.
ft.
ft.
9.8425
13.1234 16.4042 19.6850 22.9659 26.2467 29.5276
m
-
LA
-
0
TI N
Meters to Feet
10 32.8084 36.0892 39.3701 42.6509 45.9318 49.2126 52.4934 55.7743 59.0551 62.3360 10 20 65.6168 68.8976 72.1785 75.4593 78.7402 82.0210 85.3018 88.5827 91.8635 95.1444 20 30 98.4252 101.7060 104.9869 108.2677 111.5486 114.8294 118.1102 121.3911 124.6719 127.9528 30
NY
40 131.2336 134.5144 137.7953 141.0761 144.3570 147.6378 150.9186 154.1995 157.4803 160.7612 40 50 164.0420 167.3228 170.6037 173.8845 177.1654 180.4462 183.7270 187.0079 190.2887 193.5696 50
SA
60 196.8504 200.1312 203.4121 206.6929 209.9738 213.2546 216.5354 219.8163 223.0971 226.3780 60 70 229.6588 232.9396 236.2205 239.5013 242.7822 246.0630 249.3438 252.6247 255.9055 259.1864 70 80 262.4672 265.7480 269.0289 272.3097 275.5906 278.8714 282.1522 285.4331 288.7139 291.9948 80 90 295.2756 298.5564 301.8373 305.1181 308.3990 311.6798 314.9606 318.2415 321.5223 324.8032 90 100 328.0840 331.3648 334.6457 337.9265 341.2074 344.4882 347.7690 351.0499 354.3307 357.6116 100
Shop Manual - June 2013
1-27
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
Miles to Kilometers 1
2
3
4
5
6
7
8
9
km
km
km
km
km
km
km
km
km
km
-
-
1.609
3.219
4.828
6.437
8.047
9.656
11.265
12.875
14.484
-
10
16.093
17.703
19.312
20.921
22.531
24.140
25.749
27.359
28.968
30.577
10
20
32.187
33.796
35.405
37.015
38.624
40.234
41.843
43.452
45.062
46.671
20
30
48.280
49.890
51.499
53.108
54.718
56.327
57.936
59.546
61.155
62.764
30
40
64.374
65.983
67.592
69.202
70.811
72.420
74.030
75.639
77.248
50
80.467
82.077
83.686
85.295
86.904
88.514
90.123
91.732
94.951
50
60
96.561
98.170
99.779 101.388 102.998 104.607 106.216 107.826 109.435 111.044
60
70
112.654 114.263 115.872 117.482 119.091 120.701 122.310 123.919 125.529 127.138
70
80
128.748 130.357 131.966 133.575 135.185 136.794 138.403 140.013 141.622 143.231
80
90
144.841 146.450 148.059 149.669 151.278 152.887 154.497 156.106 157.715 159.325
A
0
RI C
78.858
93.342
AM E
miles
miles
40
90
100 160.934 162.543 164.153 165.762 167.371 168.981 170.590 172.199 173.809 175.418 100
0
1
2
3
5
6
7
8
9
miles
miles
miles
miles
miles
miles
miles
miles
miles
miles
-
-
0.621
1.243
1.864
2.485
3.107
3.728
4.350
4.971
5.592
-
10
6.214
6.835
7.456
8.078
8.699
9.321
9.942
10.563
11.185
11.806
10
20
12.427
13.049
13.670
14.292
14.913
15.534
16.156
16.777
17.398
18.020
20
30
18.641
19.262
19.884
20.505
21.127
21.748
22.369
22.991
23.612
24.233
30
40
24.855
25.476
26.098
26.719
27.340
27.962
28.583
29.204
29.826
30.447
40
50
31.069
31.690
32.311
32.933
33.554
34.175
34.797
35.418
36.039
36.661
50
60
37.282
37.904
38.525
39.146
39.768
40.389
41.010
41.632
42.253
42.875
60
70
43.496
44.117
44.739
45.360
45.981
46.603
47.224
47.845
48.467
49.088
70
80
49.710
50.331
50.952
51.574
52.195
52.816
53.438
54.059
54.681
55.302
80
90
55.923
56.545
57.166
57.787
58.409
59.030
59.652
60.273
60.894
61.516
90
100
62.137
62.758
63.380
64.001
64.622
65.244
65.865
66.487
67.108
67.729
100
1-28
NY
LA
4
SA
km
TI N
Kilometers to Miles
Shop Manual - June 2013
km
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
Area Square inches to square centimeters in2
in2
1
2
3
4
5
6
7
8
9
cm2
cm2
cm2
cm2
cm2
cm2
cm2
cm2
cm2
cm2
-
-
6.452
12.903
19.355
25.806
32.258
38.710
45.161
51.613
58.064
10
64.516
70.968
77.419
83.871
90.322
96.774 103.226 109.677 116.129 122.580
10
20
129.032 135.484 141.935 148.387 154.838 161.290 167.742 174.193 180.645 187.096
20
30
193.548 200.000 206.451 212.903 219.354 225.806 232.258 238.709 245.161 251.612
30
40
258.064 264.516 270.967 277.419 283.870 290.322 296.774 303.225 309.677 316.128
40
50
322.580 329.032 335.483 341.935 348.386 354.838 361.290 367.741 374.193 380.644
50
60
387.096 393.548 399.999 406.451 412.902 419.354 425.806 432.257 438.709 445.160
60
70
451.612 458.064 464.515 470.967 477.418 483.870 490.322 496.773 503.225 509.676
70
80
516.128 522.580 529.031 535.483 541.934 548.386 554.838 561.289 567.741 574.192
80
90
580.644 587.096 593.547 599.999 606.450 612.902 619.354 625.805 632.257 638.708
90
AM E
RI C
A
0
-
100 645.160 651.612 658.063 664.515 670.966 677.418 683.870 690.321 696.773 703.224 100
1
2
4
5
6
7
8
9
in2
in2
in2
in2
in2
in2
in2
in2
in2
in2
-
-
0.155
0.310
0.465
0.620
0.775
0.930
1.085
1.240
1.395
-
10
1.550
1.705
1.860
2.015
2.170
2.325
2.480
2.635
2.790
2.945
10
20
3.100
3.255
3.410
3.565
3.720
3.875
4.030
4.185
4.340
4.495
20
30
4.650
4.805
4.960
5.115
5.270
5.425
5.580
5.735
5.890
6.045
30
40
6.200
6.355
6.510
6.665
6.820
6.975
7.130
7.285
7.440
7.595
40
50
7.750
7.905
8.060
8.215
8.370
8.525
8.680
8.835
8.990
9.145
50
60
9.300
9.455
9.610
9.765
9.920
10.075
10.230
10.385
10.540
10.695
60
70
10.850
11.005
11.160
11.315
11.470
11.625
11.780
11.935
12.090
12.245
70
80
12.400
12.555
12.710
12.865
13.020
13.175
13.330
13.485
13.640
13.795
80
90
13.950
14.105
14.260
14.415
14.570
14.725
14.880
15.035
15.190
15.345
90
100
15.500
15.655
15.810
15.965
16.120
16.275
16.430
16.585
16.740
16.895
100
SA
NY
0
cm2
3
LA
cm2
TI N
Square centimeters to square inches
Shop Manual - June 2013
1-29
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
Volume Cubic inches to cubic centimeters in3
0
1
2
3
4
5
6
7
8
9
in3
cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) -
-
16.387
32.774
49.161
65.548
81.935
98.322
114.709 131.096 147.484
-
10 163.871 180.258 196.645 213.032 229.419 245.806 262.193 278.580 294.967 311.354 10
A
20 327.741 344.128 360.515 376.902 393.289 409.677 426.064 442.451 458.838 475.225 20 30 491.612 507.999 524.386 540.773 557.160 573.547 589.934 606.321 622.708 639.095 30
RI C
40 655.482 671.869 688.257 704.644 721.031 737.418 753.805 770.192 786.579 802.966 40 50 819.353 835.740 852.127 868.514 884.901 901.288 917.675 934.062 950.449 966.837 50 60 983.224 999.611 1015.998 1032.385 1048.772 1065.159 1081.546 1097.933 1114.320 1130.707 60
AM E
70 1147.094 1163.481 1179.868 1196.255 1212.642 1229.030 1245.417 1261.804 1278.191 1294.578 70 80 1310.965 1327.352 1343.739 1360.126 1376.513 1392.900 1409.287 1425.674 1442.061 1458.448 80 90 1474.835 1491.222 1507.610 1523.997 1540.384 1556.771 1573.158 1589.545 1605.932 1622.319 90 100 1638.706 1655.093 1671.480 1687.867 1704.254 1720.641 1737.028 1753.415 1769.802 1786.190 100
cm3 (cc)
0
1 3
3 3
4
3
in
in
-
-
0.0610
0.1220
10
0.6102
0.6713
20
1.2205
30
3
3
6
7 3
8 3
cm3
9 3
(cc) 3
in
in
in
in
in
in
0.1831
0.2441
0.3051
0.3661
0.4272
0.4882
0.5492
-
0.7323
0.7933
0.8543
0.9153
0.9764
1.0374
1.0984
1.1594
10
1.2815
1.3425
1.4035
1.4646
1.5256
1.5866
1.6476
1.7086
1.7697
20
1.8307
1.8917
1.9527
2.0138
2.0748
2.1358
2.1968
2.2579
2.3189
2.3799
30
40
2.4409
2.5019
2.5630
2.6240
2.6850
2.7460
2.8071
2.8681
2.9291
2.9901
40
50
3.0512
3.1122
3.1732
3.2342
3.2952
3.3563
3.4173
3.4783
3.5393
3.6004
50
60
3.6614
3.7224
3.7834
3.8444
3.9055
3.9665
4.0275
4.0885
4.1496
4.2106
60
70
4.2716
4.3326
4.3937
4.4547
4.5157
4.5767
4.6377
4.6988
4.7598
4.8208
70
80
4.8818
4.9429
5.0039
5.0649
5.1259
5.1870
5.2480
5.3090
5.3700
5.4310
80
90
5.4921
5.5531
5.6141
5.6751
5.7362
5.7972
5.8582
5.9192
5.9803
6.0413
90
100
6.1023
6.1633
6.2243
6.2854
6.3464
6.4074
6.4684
6.5295
6.5905
6.6515
100
1-30
LA
in
SA
in
5
NY
3
2
TI N
Cubic centimeters to cubic inches
Shop Manual - June 2013
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
U.S. Gallons to liters U.S. gal -
0
1
2
3
4
5
6
7
8
9
liters
liters
liters
liters
liters
liters
liters
liters
liters
liters
-
3.7854
7.5709
11.3563 15.1417 18.9271 22.7126 26.4980 30.2834 34.0688
U.S. gal -
37.8543 41.6397 45.4251 49.2106 52.9960 56.7814 60.5668 64.3523 68.1377 71.9231
10
20
75.7085 79.4940 83.2794 87.0648 90.8502 94.6357 98.4211 102.2065 105.9920 109.7774
20
30
113.5628 117.3482 121.1337 124.9191 128.7045 132.4899 136.2754 140.0608 143.8462 147.6317
30
40
151.4171 155.2025 158.9879 162.7734 166.5588 170.3442 174.1296 177.9151 181.7005 185.4859
40
50
189.2714 193.0568 196.8422 200.6276 204.4131 208.1985 211.9839 215.7693 219.5548 223.3402
50
60
227.1256 230.9110 234.6965 238.4819 242.2673 246.0528 249.8382 253.6236 257.4090 261.1945
60
70
264.9799 268.7653 272.5507 276.3362 280.1216 283.9070 287.6925 291.4779 295.2633 299.0487
70
80
302.8342 306.6196 310.4050 314.1904 317.9759 321.7613 325.5467 329.3321 333.1176 336.9030
80
90
340.6884 344.4739 348.2593 352.0447 355.8301 359.6156 363.4010 367.1864 370.9718 374.7573
90
AM E
RI C
A
10
100 378.5427 382.3281 386.1136 389.8990 393.6844 397.4698 401.2553 405.0407 408.8261 412.6115 100
3
4
5
6
7
8
9
gal
gal
gal
gal
gal
gal
gal
0.7925
1.0567
1.3209
1.5850
1.8492
2.1134
2.3775
-
LA
1
2
gal
gal
gal
-
-
0.2642
0.5283
10
2.6417
2.9059
3.1701
3.4342
3.6984
3.9626
4.2268
4.4909
4.7551
5.0193
10
20
5.2834
5.5476
5.8118
6.0760
6.3401
6.6043
6.8685
7.1326
7.3968
7.6610
20
30
7.9252
8.1893
8.4535
8.7177
8.9818
9.2460
9.5102
9.7744 10.0385 10.3027
30
40
10.5669 10.8311 11.0952 11.3594 11.6236 11.8877 12.1519 12.4161 12.6803 12.9444
40
50
13.2086 13.4728 13.7369 14.0011 14.2653 14.5295 14.7936 15.0578 15.3220 15.5861
50
60
15.8503 16.1145 16.3787 16.6428 16.9070 17.1712 17.4354 17.6995 17.9637 18.2279
60
NY
0
SA
liters
TI N
Liters to U.S. Gallons liters
70
18.4920 18.7562 19.0204 19.2846 19.5487 19.8129 20.0771 20.3412 20.6054 20.8696
70
80
21.1338 21.3979 21.6621 21.9263 22.1904 22.4546 22.7188 22.9830 23.2471 23.5113
80
90
23.7755 24.0397 24.3038 24.5680 24.8322 25.0963 25.3605 25.6247 25.8889 26.1530
90
100 26.4172 26.6814 26.9455 27.2097 27.4739 27.7381 28.0022 28.2664 28.5306 28.7947 100
Shop Manual - June 2013
1-31
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
U.K. Gallons to Liters lmp gal -
0
1
2
3
4
5
6
7
8
9
liters
liters
liters
liters
liters
liters
liters
liters
liters
liters
-
4.5459
9.0918
13.6377 18.1836 22.7295 27.2754 31.8213 36.3672 40.9131
lmp gal -
45.4590 50.0049 54.5508 59.0967 63.6426 68.1885 72.7344 77.2803 81.8262 86.3721
10
20
90.9180 95.4639 100.0098 104.5557 109.1016 113.6475 118.1934 122.7393 127.2852 131.8311
20
30
136.3770 140.9229 145.4688 150.0147 154.5606 159.1065 163.6524 168.1983 172.7442 177.2901
30
40
181.8360 186.3819 190.9278 195.4737 200.0196 204.5655 209.1114 213.6573 218.2032 222.7491
40
50
227.2950 231.8409 236.3868 240.9327 245.4786 250.0245 254.5704 259.1163 263.6622 268.2081
50
60
272.7540 277.2999 281.8458 286.3917 290.9376 295.4835 300.0294 304.5753 309.1212 313.6671
60
70
318.2130 322.7589 327.3048 331.8507 336.3966 340.9425 345.4884 350.0343 354.5802 359.1261
70
80
363.6720 368.2179 372.7638 377.3097 381.8556 386.4015 390.9474 395.4933 400.0392 404.5851
80
90
409.1310 413.6769 418.2228 422.7687 427.3146 431.8605 436.4064 440.9523 445.4982 450.0441
90
AM E
RI C
A
10
100 454.5900 459.1359 463.6818 468.2277 472.7736 477.3195 481.8654 486.4113 490.9572 495.5031 100
1
2
3
4
5
6
7
8
9
gal
gal
gal
gal
gal
gal
gal
gal
gal
gal
-
-
0.2200
0.4400
0.6599
0.8799
1.0999
1.3199
1.5399
1.7598
1.9798
-
10
2.1998
2.4198
2.6398
2.8597
3.0797
3.2997
3.5197
3.7397
3.9596
4.1796
10
20
4.3996
4.6196
4.8396
5.0595
5.2795
5.4995
5.7195
5.9395
6.1594
6.3794
20
30
6.5994
6.8194
7.0394
7.2593
7.4793
7.6993
7.9193
8.1393
8.3592
8.5792
30
40
8.7992
9.0192
9.2392
9.4591
9.6791
9.8991 10.1191 10.3391 10.5590 10.7790
40
50
10.9990 11.2190 11.4390 11.6589 11.8789 12.0989 12.3189 12.5389 12.7588 12.9788
50
60
13.1988 13.4188 13.6388 13.8587 14.0787 14.2987 14.5187 14.7387 14.9586 15.1786
60
70
15.3986 15.6186 15.8386 16.0585 16.2785 16.4985 16.7185 16.9385 17.1584 17.3784
70
80
17.5984 17.8184 18.0384 18.2583 18.4783 18.6983 18.9183 19.1383 19.3582 19.5782
80
90
19.7982 20.0182 20.2382 20.4581 20.6781 20.8981 21.1181 21.3381 21.5580 21.7780
90
NY
LA
0
SA
liters
TI N
Liters to U.K. Gallons liters
100 21.9980 22.2180 22.4380 22.6579 22.8779 23.0979 23.3179 23.5379 23.7578 23.9778 100
1-32
Shop Manual - June 2013
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
Weight
2
3
4
5
6
7
8
9
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
-
-
0.454
0.907
1.361
1.814
2.268
2.722
3.175
3.629
4.082
-
10
4.536
4.989
5.443
5.897
6.350
6.804
7.257
7.711
8.165
8.618
10
20
9.072
9.525
9.979
10.433
10.886
11.340
11.793
12.247
12.701
13.154
20
30
13.608
14.061
14.515
14.968
15.422
15.876
16.329
16.783
17.236
17.690
30
40
18.144
18.597
19.051
19.504
19.958
20.412
20.865
21.319
21.772
22.226
40
50
22.680
23.133
23.587
24.040
24.494
24.947
25.401
25.855
26.308
26.762
50
60
27.215
27.669
28.123
28.576
29.030
29.483
29.937
30.391
30.844
31.298
60
70
31.751
32.205
32.658
33.112
33.566
34.019
34.473
34.926
35.380
35.834
70
80
36.287
36.741
37.194
37.648
38.102
38.555
39.009
39.462
39.916
40.370
80
90
40.823
41.277
41.730
42.184
42.637
43.091
43.545
43.998
44.452
44.905
90
100 45.359
45.813
46.266
46.720
47.173
47.627
48.081
48.534
48.988
49.441 100
Kilogram to Pound 1
2
lbs.
lbs.
lbs.
-
-
2.205
10
22.046
20
44.092
30
66.139
68.343
40
88.185
90.389
lbs.
3
4
5
6
7
8
9
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
4.409
6.614
8.818
11.023
13.228
15.432
17.637
19.842
-
24.251
26.455
28.660
30.865
33.069
35.274
37.479
39.683
41.888
10
46.297
48.502
50.706
52.911
55.116
57.320
59.525
61.729
63.934
20
70.548
72.752
74.957
77.162
79.366
81.571
83.776
85.980
30
92.594
94.799
97.003
99.208 101.413 103.617 105.822 108.026
40
50
110.231 112.436 114.640 116.845 119.049 121.254 123.459 125.663 127.868 130.073
50
60
132.277 134.482 136.686 138.891 141.096 143.300 145.505 147.710 149.914 152.119
60
70
154.323 156.528 158.733 160.937 163.142 165.347 167.551 169.756 171.960 174.165
70
80
176.370 178.574 180.779 182.983 185.188 187.393 189.597 191.802 194.007 196.211
80
90
198.416 200.620 202.825 205.030 207.234 209.439 211.644 213.848 216.053 218.257
90
NY
LA
0
SA
kg
A
1
TI N
lbs.
AM E
0
RI C
Pound to Kilogram
kg
100 220.462 222.667 224.871 227.076 229.280 231.485 233.690 235.894 238.099 240.304 100
Shop Manual - June 2013
1-33
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
Newton to Kilogram 10
20
30
40
50
60
70
80
90
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
-
-
1.020
2.039
3.059
4.079
5.099
6.118
7.138
8.158
9.177
-
100
10.197
11.217
12.237
13.256
14.276
15.296
16.316
17.335
18.355
19.375
100
200
20.394
21.414
22.434
23.454
24.473
25.493
26.513
27.532
28.552
29.572
200
300
30.592
31.611
32.631
33.651
34.670
35.690
36.710
37.730
38.749
39.769
300
400
40.789
41.809
42.828
43.848
44.868
45.887
46.907
47.927
48.947
500
50.986
52.006
53.025
54.045
55.065
56.085
57.104
58.124
59.144
60.163
500
600
61.183
62.203
63.223
64.242
65.262
66.282
67.302
68.321
69.341
70.361
600
700
71.380
72.400
73.420
74.440
75.459
76.479
77.499
78.518
79.538
80.558
700
800
81.578
82.597
83.617
84.637
85.656
86.676
87.696
88.716
89.735
90.755
800
900
91.775
92.795
93.814
94.834
95.854
96.873
97.893
A
0
49.966
RI C
AM E
N
98.913
N
400
99.933 100.952 900
1000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 1000
1
2
3
5
6
7
8
9
N
N
N
N
N
N
N
N
N
N
-
-
9.81
19.61
29.42
39.23
49.03
58.84
68.65
78.45
88.26
-
10
98.07
107.87
117.68
127.49
137.29
147.10
156.91
166.71
176.52
186.33
10
20
196.13
205.94
215.75
225.55
235.36
245.17
254.97
264.78
274.59
284.39
20
30
294.20
304.01
313.81
323.62
333.43
343.23
353.04
362.85
372.65
382.46
30
40
392.27
402.07
411.88
421.69
431.49
441.30
451.11
460.91
470.72
480.53
40
50
490.34
500.14
509.95
519.76
529.56
539.37
549.18
558.98
568.79
578.60
50
60
588.40
598.21
608.02
617.82
627.63
637.44
647.24
657.05
666.86
676.66
60
70
686.47
696.28
706.08
715.89
725.70
735.50
745.31
755.12
764.92
774.73
70
80
784.54
794.34
804.15
813.96
823.76
833.57
843.38
853.18
862.99
872.80
80
90
882.60
892.41
902.22
912.02
921.83
931.64
941.44
951.25
961.06
970.86
90
100
980.67
990.48 1000.28 1010.09 1019.90 1029.70 1039.51 1049.32 1059.12 1068.93 100
1-34
LA
4
NY
0
SA
kg
TI N
Kilogram to Newton
Shop Manual - June 2013
kg
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
Pressure Lb/in² to Kg/cm² lb/ 0 1 2 3 4 5 6 7 8 9 lb/in2 in2 (psi) kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 (psi) -
0.0703
0.1406
0.2109
0.2812
0.3515
0.4218
0.4921
0.5625
0.6328
-
10
0.7031
0.7734
0.8437
0.9140
0.9843
1.0546
1.1249
1.1952
1.2655
1.3358
10
20
1.4061
1.4764
1.5468
1.6171
1.6874
1.7577
1.8280
1.8983
1.9686
2.0389
20
30
2.1092
2.1795
2.2498
2.3201
2.3904
2.4607
2.5311
2.6014
2.6717
2.7420
30
40
2.8123
2.8826
2.9529
3.0232
3.0935
3.1638
3.2341
3.3044
3.3747
3.4450
40
50
3.5154
3.5857
3.6560
3.7263
3.7966
3.8669
3.9372
4.0075
4.0778
4.1481
50
60
4.2184
4.2887
4.3590
4.4293
4.4996
4.5700
4.6403
4.7106
4.7809
4.8512
60
70
4.9215
4.9918
5.0621
5.1324
5.2027
5.2730
5.3433
5.4136
5.4839
5.5543
70
80
5.6246
5.6949
5.7652
5.8355
5.9058
5.9761
6.0464
6.1167
6.1870
6.2573
80
90
6.3276
6.3979
6.4682
6.5386
6.6089
6.6792
6.7495
6.8198
6.8901
6.9604
90
100
7.0307
7.1010
7.1713
7.2416
7.3119
7.3822
7.4525
7.5228
7.5932
7.6635
100
-
0
1
2
lb/in2
lb/in2
lb/in2
(psi) -
(psi) 14.22
(psi) 28.45
RI C
AM E
TI N
kg/ cm2
LA
Kg/cm² to Lb/in²
A
-
3
4
5
6
7
8
9
lb/in2
lb/in2
lb/in2
lb/in2
lb/in2
lb/in2
lb/in2
(psi) 56.89
(psi) 71.12
(psi) 85.34
(psi) 99.56
(psi) 42.67
(psi) (psi) 113.78 128.01
kg/cm2
-
142.23 156.45 170.68 184.90 199.12 213.35 227.57 241.79 256.01 270.24
10
20
284.46 298.68 312.91 327.13 341.35 355.58 369.80 384.02 398.24 412.47
20
30
426.69 440.91 455.14 469.36 483.58 497.81 512.03 526.25 540.47 554.70
30
40
568.92 583.14 597.37 611.59 625.81 640.04 654.26 668.48 682.70 696.93
40
50
711.15 725.37 739.60 753.82 768.04 782.27 796.49 810.71 824.93 839.16
50
60
853.38 867.60 881.83 896.05 910.27 924.50 938.72 952.94 967.16 981.39
60
70
995.61 1009.83 1024.06 1038.28 1052.50 1066.73 1080.95 1095.17 1109.39 1123.62
70
80
1137.84 1152.06 1166.29 1180.51 1194.73 1208.96 1223.18 1237.40 1251.62 1265.85
80
90
1280.07 1294.29 1308.52 1322.74 1336.96 1351.19 1365.41 1379.63 1393.85 1408.08
90
100
1422.30 1436.52 1450.75 1464.97 1479.19 1493.42 1507.64 1521.86 1536.08 1550.31
100
SA
NY
10
Shop Manual - June 2013
1-35
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
Kg/cm² to Kpa kg/ cm2
kg/ cm2
1
2
3
4
5
6
7
8
9
Kpa
Kpa
Kpa
Kpa
Kpa
Kpa
Kpa
Kpa
Kpa
Kpa
-
-
98.1
196.1
294.2
392.3
490.3
588.4
686.5
784.5
882.6
10
980.7
1078.7
1176.8
1274.9 1372.9 1471.0 1569.1 1667.1 1765.2 1863.3
10
20
1961.3 2059.4 2157.5 2255.5 2353.6 2451.7 2549.7 2647.8 2745.9 2843.9
20
30
2942.0 3040.1 3138.1 3236.2 3334.3 3432.3 3530.4 3628.5 3726.5 3824.6
30
40
3922.7 4020.7
4609.1 4707.2 4805.3
40
50
4903.4 5001.4 5099.5 5197.6 5295.6 5393.7 5491.8 5589.8 5687.9 5786.0
50
60
5884.0 5982.1 6080.2 6178.2 6276.3 6374.4 6472.4 6570.5 6668.6 6766.6
60
70
6864.7 6962.8 7060.8 7158.9 7257.0 7355.0 7453.1 7551.2 7649.2 7747.3
70
80
7845.4 7943.4 8041.5 8139.6 8237.6 8335.7 8433.8 8531.8 8629.9 8728.0
80
90
8826.0 8924.1 9022.2 9120.2 9218.3 9316.4 9414.4 9512.5 9610.6 9708.6
90
100
9806.7 9904.8 10002.8 10100.9 10199.0 10297.0 10395.1 10493.2 10591.2 10689.3
100
4511.1
RI C
4216.9 4314.9 4413.0
AM E
4118.8
A
0
-
Kpa
0
100
200
300
TI N
Kpa to Kg/cm² 400
500
600
700
800
900
Kpa
kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 -
1.020
2.039
1000
10.197
11.217
12.237
13.256
2000
20.394
21.414
22.434
3000
30.592
31.611
4000
40.789
5000
50.986
6000
61.183
7000
71.380
9000
5.099
6.118
7.138
8.158
9.177
-
14.276
15.296
16.316
17.335
18.355
19.375
1000
23.454
24.473
25.493
26.513
27.532
28.552
29.572
2000
32.631
33.651
34.670
35.690
36.710
37.730
38.749
39.769
3000
41.809
42.828
43.848
44.868
45.887
46.907
47.927
48.947
49.966
4000
52.006
53.025
54.045
55.065
56.085
57.104
58.124
59.144
60.163
5000
62.203
63.223
64.242
65.262
66.282
67.302
68.321
69.341
70.361
6000
72.400
73.420
74.440
75.459
76.479
77.499
78.518
79.538
80.558
7000
81.578
82.597
83.617
84.637
85.656
86.676
87.696
88.716
89.735
90.755
8000
91.775
92.795
93.814
94.834
95.854
96.873
97.893
98.913
99.933 100.952 9000
NY
SA
8000
3.059
4.079
LA
-
10000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 10000
1-36
Shop Manual - June 2013
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
Torque Ft·lbs to Kg·m 1
2
3
4
5
6
7
8
9
kg·m
kg·m
kg·m
kg·m
kg·m
kg·m
kg·m
kg·m
kg·m
kg·m
-
-
0.138
0.277
0.415
0.553
0.691
0.830
0.968
1.106
1.244
-
10
1.383
1.521
1.659
1.797
1.936
2.074
2.212
2.350
2.489
2.627
10
20
2.765
2.903
3.042
3.180
3.318
3.457
3.595
3.733
3.871
4.010
20
30
4.148
4.286
4.424
4.563
4.701
4.839
4.977
5.116
5.254
5.392
30
40
5.530
5.669
5.807
5.945
6.083
6.222
6.360
50
6.913
7.051
7.190
7.328
7.466
7.604
7.743
60
8.296
8.434
8.572
8.710
8.849
8.987
9.125
70
9.678
9.816
9.955
10.093
10.231
10.370
80
11.061
11.199
11.337
11.476
11.614
90
12.443
12.582
12.720
12.858
100
13.826
13.964
14.103
14.241
0
1
2
ft·lbs
ft·lbs
-
-
10
Kg·m to Ft·lbs
RI C
ft·lbs
6.636
6.775
40
7.881
8.019
8.157
50
9.263
9.402
9.540
60
10.508
10.646
10.784
10.923
70
11.752
11.890
12.029
12.167
12.305
80
12.996
13.135
13.273
13.411
13.549
13.688
90
14.379
14.517
14.656
14.794
14.932
15.070
100
kg·m
AM E
6.498
4
5
6
7
8
9
ft·lbs
ft·lbs
ft·lbs
ft·lbs
ft·lbs
ft·lbs
ft·lbs
ft·lbs
7.23
14.47
21.70
28.93
36.17
43.40
50.63
57.86
65.10
-
72.33
79.56
86.80
94.03
101.26
108.50
115.73
122.96
130.19
137.43
10
20
144.66
151.89
159.13
166.36
173.59
180.83
188.06
195.29
202.52
209.76
20
30
216.99
224.22
231.46
238.69
245.92
253.16
260.39
267.62
274.85
282.09
30
40
289.32
296.55
303.79
311.02
318.25
325.49
332.72
339.95
347.18
354.42
40
50
361.65
368.88
376.12
383.35
390.58
397.82
405.05
412.28
419.51
426.75
50
60
433.98
441.21
448.45
455.68
462.91
470.15
477.38
484.61
491.84
499.08
60
70
506.31
513.54
520.78
528.01
535.24
542.48
549.71
556.94
564.17
571.41
70
80
578.64
585.87
593.11
600.34
607.57
614.81
622.04
629.27
636.50
643.74
80
90
650.97
658.20
665.44
672.67
679.90
687.14
694.37
701.60
708.83
716.07
90
100
723.30
730.53
737.77
745.00
752.23
759.47
766.70
773.93
781.16
788.40
100
NY
LA
3
SA
kg·m
A
0
TI N
ft·lbs
Shop Manual - June 2013
1-37
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
Kg·m to N·m 1
2
3
4
5
6
7
8
9
N·m
N·m
N·m
N·m
N·m
N·m
N·m
N·m
N·m
N·m
-
-
9.81
19.61
29.42
39.23
49.03
58.84
68.65
78.45
88.26
-
10
98.07
107.87
117.68
127.49
137.29
147.10
156.91
166.71
176.52
186.33
10
20
196.13
205.94
215.75
225.55
235.36
245.17
254.97
264.78
274.59
284.39
20
30
294.20
304.01
313.81
323.62
333.43
343.23
353.04
362.85
372.65
382.46
30
40
392.27
402.07
411.88
421.69
431.49
441.30
451.11
460.91
470.72
50
490.34
500.14
509.95
519.76
529.56
539.37
549.18
558.98
568.79
578.60
50
60
588.40
598.21
608.02
617.82
627.63
637.44
647.24
657.05
666.86
676.66
60
70
686.47
696.28
706.08
715.89
725.70
735.50
745.31
755.12
764.92
774.73
70
80
784.54
794.34
804.15
813.96
823.76
833.57
843.38
853.18
862.99
872.80
80
90
882.60
892.41
902.22
912.02
921.83
931.64
961.06
970.86
90
100
980.67
990.48 1000.28 1010.09 1019.90 1029.70 1039.51 1049.32 1059.12 1068.93 100
941.44
A
0
480.53
RI C
AM E
kg·m
951.25
kg·m
40
10
20
30
50
60
70
80
90
kg·m
kg·m
kg·m
kg·m
kg·m
kg·m
kg·m
kg·m
kg·m
kg·m
-
-
1.020
2.039
3.059
4.079
5.099
6.118
7.138
8.158
9.177
-
100
10.197
11.217
12.237
13.256
14.276
15.296
16.316
17.335
18.355
19.375
10
200
20.394
21.414
22.434
23.454
24.473
25.493
26.513
27.532
28.552
29.572
20
300
30.592
31.611
32.631
33.651
34.670
35.690
36.710
37.730
38.749
39.769
30
400
40.789
41.809
42.828
43.848
44.868
45.887
46.907
47.927
48.947
49.966
40
500
50.986
52.006
53.025
54.045
55.065
56.085
57.104
58.124
59.144
60.163
50
600
61.183
62.203
63.223
64.242
65.262
66.282
67.302
68.321
69.341
70.361
60
700
71.380
72.400
73.420
74.440
75.459
76.479
77.499
78.518
79.538
80.558
70
800
81.578
82.597
83.617
84.637
85.656
86.676
87.696
88.716
89.735
90.755
80
900
91.775
92.795
93.814
94.834
95.854
96.873
97.893
98.913
99.933 100.952
90
LA
40
NY
0
SA
N·m
TI N
N·m to Kg·m N·m
1000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 100
1-38
Shop Manual - June 2013
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
Temperature A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading (or vice versa) is to enter the following table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. To convert from Fahrenheit to Centigrade degrees, consider the center column as Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
SA
NY
LA
TI N
AM E
RI C
A
To convert from Centigrade to Fahrenheit degrees, consider the center column as Centigrade values, and read the corresponding Fahrenheit temperature on the right.
Shop Manual - June 2013
1-39
Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator
1°C = 33.8°F °F
°C
°F
°C
°F
°C
°F
-40
-40.0
-11.7
11
51.8
7.8
46
114.8
27.2
81
177.8
-37.2
-35
-31.0
-11.1
12
53.6
8.3
47
116.6
27.8
82
179.6
-34.4
-30
-22.0
-10.6
13
55.4
8.9
48
118.4
28.3
83
181.4
-31.7
-25
-13.0
-10.0
14
57.2
9.4
49
120.2
28.9
84
183.2
-28.9 -28.3
-2 -20 -19
-4.0 -2.2
-9.4 -8.9
15 16
59.0 60.8
10.0 10.6
50 51
122.0 123.8
29.4 30.0
85 86
185.0 186.8
-27.8
-18
-0.4
-8.3
17
62.6
11.1
52
125.6
30.6
87
188.6
-27.2
-17
1.4
-7.8
18
64.4
11.7
53
127.4
31.1
88
190.4
-26.7
-16
3.2
-7.2
19
66.2
12.2
54
129.2
31.7
89
192.2
-26.1 -25.6
-15 -14
5.0 6.8
-6.7 -6.1
20 21
68.0 69.8
12.8 13.3
55 56
131.0 132.8
32.2 32.8
90 91
194.0 195.8
-25.0
-13
8.6
-5.6
22
71.6
13.9
57
134.6
33.3
92
197.6
-24.4
-12
10.4
-5.0
23
73.4
14.4
58
136.4
33.9
93
199.4
-23.9
-11
12.2
-4.4
24
75.2
15.0
59
138.2
34.4
94
201.2
-23.3 -22.8
-10 -9
14.0 15.8
-3.9 -3.3
25 26
77.0 78.8
15.6 16.1
60 61
140.0 141.8
35.0 35.6
95 96
203.0 204.8
-22.2
-8
17.6
-2.8
27
-21.7
-7
19.4
-2.2
28
-21.1
-6
21.2
-1.7
29
-20.6 -20.0
-5 -4
23.0 24.8
-1.1 -0.6
30 31
-19.4
-3
26.6
0.0
-18.9
-2
28.4
-18.3
-1
-17.8 -17.2
0 1
-16.7
2
TI N
AM E
RI C
-40.0
A
°C
16.7
62
143.6
36.1
97
206.6
82.4
17.2
63
145.4
36.7
98
208.4
84.2
17.8
64
147.2
37.2
99
210.2
86.0 87.8
18.3 18.9
65 66
149.0 150.8
37.8 40.6
100 105
212.0 221.0
32
89.6
19.4
67
152.6
43.3
110
230.0
0.6
33
91.4
20.0
68
154.4
46.1
115
239.0
30.2
1.1
34
93.2
20.6
69
156.2
48.9
120
248.0
32.0 33.8
1.7 2.2
35 36
95.0 96.8
21.1 21.7
70 71
158.0 159.8
51.7 54.4
125 130
257.0 266.0
35.6
2.8
37
98.6
22.2
72
161.6
57.2
135
275.0
3
37.4
3.3
38
100.4
22.8
73
163.4
60.0
140
284.0
4
39.2
3.9
39
102.2
23.3
74
165.2
62.8
145
293.0
-15.0 -14.4
5 6
41.0 42.8
4.4 5.0
40 41
104.0 105.8
23.9 24.4
75 76
167.0 168.8
65.6 68.3
150 155
302.0 311.0
-13.9
7
44.6
5.6
42
107.6
25.0
77
170.6
71.1
160
320.0
-13.3
8
46.4
6.1
43
109.4
25.6
78
172.4
73.9
165
329.0
-12.8
9
48.2
6.7
44
111.2
26.1
79
174.2
76.7
170
338.0
-12.2
10
50.0
7.2
45
113.0
26.7
80
176.0
79.4
175
347.0
-15.6
1-40
NY
SA
-16.1
LA
80.6
Shop Manual - June 2013
Introduction
SA
BLNY ANLA TI KN PAAM E G RI E CA
SY195/205/215/225C9 Crawler Hydraulic Excavator
Shop Manual - June 2013
1-41
SY195/205/215/225C9 Crawler Hydraulic Excavator
BSLAN AYNL AT K IN PAA M GERI E CA
Introduction
1-42
Shop Manual - June 2013
Shop Safety
RI C
Shop Safety
A
SY195/205/215/225C9 Crawler Hydraulic Excavator
2 Shop Safety
SA
NY
LA
TI N
AM E
2.1 Hazard Alert Information .......................................................................................... 2-3 2.2 General Shop Safety ............................................................................................... 2-6 2.2.1 Rules and shop behavior ............................................................................... 2-7 2.2.2 Housekeeping ................................................................................................ 2-7 2.2.3 Shop Liquids Storage..................................................................................... 2-8 2.2.4 Cleaning Parts ............................................................................................... 2-8 2.2.5 Jacking Up the Machine................................................................................. 2-9 2.2.6 Electrical Dangers .......................................................................................... 2-9 2.2.7 Removing Attachments ................................................................................ 2-10 2.2.8 Cleaning the Machine .................................................................................. 2-10 2.2.9 Using the Correct Tools................................................................................ 2-10 2.2.10 Hoisting a Load ...........................................................................................2-11 2.2.11 Appropriate Working Apparel ..................................................................... 2-12 2.2.12 Safety Partners .......................................................................................... 2-12 2.2.13 Two people when engine running .............................................................. 2-13 2.2.14 Driving Pins ................................................................................................ 2-13 2.2.15 Aligning Parts or Components ................................................................... 2-14 2.2.16 Fire Extinguisher and Emergency Exits ..................................................... 2-14 2.2.17 Personal Protective Equipment.................................................................. 2-14 2.2.18 Running the Machine ................................................................................. 2-15 2.2.19 Accumulator ............................................................................................... 2-16 2.2.20 Adding Fluids to a System ......................................................................... 2-16 2.2.21 Track Recoil Springs .................................................................................. 2-17 2.2.22 High-Pressure Fluid Lines.......................................................................... 2-17 2.2.23 Safe Work Preparations ............................................................................. 2-18 2.2.24 Mounting and Dismounting ........................................................................ 2-19 Shop Manual - June 2013
2-1
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
SA
NY
LA
TI N
AM E
RI C
A
2.2.25 Battery Hazards ......................................................................................... 2-20 2.2.26 Jump-Start Safety ...................................................................................... 2-21 2.2.27 Disconnecting the System Power .............................................................. 2-21 2.2.28 Lockout/tagout ........................................................................................... 2-22 2.2.29 Sequence of Procedures ........................................................................... 2-22 2.2.30 Chemical hazard ........................................................................................ 2-24 2.2.31 Material Safety Data Sheets (MSDS) ........................................................ 2-24 2.3 Precautions for sling work and giving signals ........................................................ 2-25
2-2
WARNING
Read and understand all safety precautions and instructions in this manual before reading any other manuals provided with this machine and before operating or servicing the machine. Also read the safety information on machine decals before performing any operations. Failure to do so can cause machine damage, personal injury or death.
Shop Manual - June 2013
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
2 SHOP SAFETY 2.1 Hazard Alert Information
DANGER
RI C AM E
TI N
The following (ANSI/ISO) signal words are used to inform you that there is a potentially hazardous situation that may lead to damage, personal injury or even death. In this manual, on the machine, part or component decals and different signal words are used to express the potential level of a hazard.
A
Most accidents are usually caused by the failure to follow fundamental repair procedures and safety rules for the system under repair. To avoid accidents it is important to read and understand all information outlined in this manual before performing repairs on the machine system.
LA
Indicates an imminent hazard which WILL result in serious injury or death if message is ignored.
WARNING
SA
NY
Indicates a potentially hazardous situation which COULD result in serious injury or death if message is ignored.
CAUTION
Indicates a potentially hazardous situation which COULD RESULT IN MINOR OR MAJOR INJURY if message is ignored.
NOTICE Indicates THE MACHINE MAY BE DAMAGED if improperly operated or maintained.
Shop Manual - June 2013
2-3
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
This is to alert the user of a hazard. It is usually used in a graphic. This symbol is used in a graphic to alert the user to not do something.
RI C AM E
SA
NY
LA
TI N
If any procedures or actions not specified, recommended or allowed in this manual are used, you must be sure that you and others can perform such procedures and actions safely and without damaging the machine. If you are unsure about the safety of some procedures, contact your SANY representative.
A
SANY cannot predict every circumstance that might involve a potential hazard in a repair of the machine. Therefore the safety message in this manual and on the machine may not include all possible safety precautions.
2-4
Shop Manual - June 2013
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
WARNING ● Improper repair procedures on this machine can be hazardous and could result in serious injury or even death.
A
● All personnel involved with the repair of this machine must read this manual thoroughly before performing any procedures on this equipment.
AM E
TI N
● All precautions outlined in this manual apply only to intended repair procedures of the machine or system. If you perform any repairs not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in prohibited uses or actions as described in this manual.
RI C
● Some actions involved in the operation or repair of this machine could cause a serious accident if they are not performed in the manner described in this manual.
SA
NY
LA
● SANY delivers machines that comply with all applicable regulations and standards of the country to which the machines have been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety features and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, contact your SANY representative before performing repairs on this machine.
Shop Manual - June 2013
2-5
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
2.2 General Shop Safety
WARNING
RI C AM E
TI N
Always keep in mind, shop safety is NOT something to be studied at the start of a project and then forgotten; most accidents are caused by carelessness, being in a hurry or by simply disreguarding safety rules. Remember this, if you are DILIGENT and follow instructions outlined in this shop manual with care, repair operations can be safe and enjoyable. Safe work practices, should become a force of habit.
A
It's important to establish good shop safety rules for everyone who enters or uses the shop area. Implementing shop safety rules will keep employees safe and provide the most productive environment for working or learning. Post rules where they can clearly be viewed at all times. If necessary, provide shop personnel with a written copy of the rules and discuss any questions or confusion with them.
SA
NY
LA
● Mistakes in operation are extremely hazardous. Read the Safety, Operation & Maintenance Manual that came with the machine carefully before operating the machine. Failure to follow this alert could result in serious injury or death.
2-6
Shop Manual - June 2013
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
2.2.1 Rules and shop behavior ● Study all shop rules relating to the procedure carefully and constantly apply them. When in doubt about any task, get help! DO NOT take chances.
RI C AM E
● The shop is a place to work, not play. It is NOT a place for “horseplay”. A “joker” in a repair shop is a “walking hazard” to everyone. Daydreaming or socializing on the job also increases your chances of injury.
A
● Know your job. It is foolish, and often disastrous, to make repairs to a machine without first receiving proper instructions. Always use the shop manual when performing any repair tasks. Get additional help if you are NOT sure what must be done or how a task should be performed.
CA13082101
TI N
● If you must smoke, smoke only in the area provided for smoking. Never smoke while on the shop floor or work area.
2.2.2 Housekeeping
NY
LA
● Oils, grease, fuel, antifreeze or any fluid spills should be mopped up immediately. These items pose a serious slip hazard. Regardless of who was responsible for the spill, it is your job as a shop employee to secure and clean up the spill area.
SA
● Keep the shop clean. Scrap or old parts should be disposed of properly. Never allow them to remain on the bench or shop floor. ● All equipment and tools must be put back in their proper storage areas after each use. It's imperative that you do not let a shop become cluttered and disorganized in order to prevent accidents.
CA13082102
● Always keep in mind, proper house cleaning is vital for a safe and pleasant work environment. Shop Manual - June 2013
2-7
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
2.2.3 Shop Liquids Storage
A
● Liquids, cleaning solvents or machine fluids should be properly stored in an area away from work locations. These storage areas should be ventilated to an outdoor location to avoid any vapor accumulation in a confined shop area. Follow all OSHA regulations regarding fluid storage.
CA13082103
TI N
● Never smoke or bring open flames around liquids, doing so could result in an unexpected fire or explosion.
AM E
● Never store liquids in containers that are not properly labeled for that liquid. Confusion could result in equipment damage, fire or an unexpected explosion.
RI C
● Never leave open containers of liquids sitting around. These could spill or catch fire. Always read the container label for information on storage and handling of the liquids.
LA
● Never handle liquids without using personal protective equipment. Treat all liquids with caution.
NY
2.2.4 Cleaning Parts
SA
Never use gasoline, diesel fuel or similar flammable liquids to clean parts. Always use approved non-flammable solvents to clean parts. Failure to do so could result in explosion or fire.
CA13082104
2-8
Shop Manual - June 2013
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
2.2.5 Jacking Up the Machine ● If you will be working under the machine always use approved jack stands that will support the weight of the machine you are working on.
A
● Never rely on the hydraulics of the machine or a hydraulic jack to support the machine during repairs.
TI N
● When testing electrical circuits, always be aware of what you will be checking in these systems. High voltage or high amp circuits could damage your equipment or cause a spark, explosion or possible fire.
CZ335-1102078
AM E
2.2.6 Electrical Dangers
RI C
● Always lower the work equipment to the ground and check the stability of the machine before going under the machine.
NY
LA
● Before performing any repairs or testing on an electrical system be sure of the system voltage dangers. Always check the circuit to be sure it is off before performing any repairs.
SA
● When working around flammable liquids or explosive systems, use only approved antiexplosion proof work lamps. Non-approved work lamps can cause an explosion or fire. CA13082105
Shop Manual - June 2013
2-9
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
2.2.7 Removing Attachments ● If you will be removing large heavy attachments from the machine, always be sure to use the correct lifting equipment rated for the capacity of the load you will be lifting.
RI C
A
● After the attachment or part has been removed, store it where it cannot fall or move. Always be sure what you are storing is sitting stable on a stable surface and clear of all walkways or fire exits.
TI N
● Always use high-pressure hot water and mild, nonflammable grease-cutting soaps or cleaning agents to clean the machine parts. Never use flammable or caustic cleaning agents.
AM E
2.2.8 Cleaning the Machine
CA13082106
LA
● Never use high-pressure steam cleaners to clean the machine. Steam cleaners will damage the paint, hoses or electrical system.
NY
● Never pressure-wash or flood the inside of an operator cab. This will damage sensitive electrical components.
SA
2.2.9 Using the Correct Tools ● Always use the proper authorized tools for the job. Using tools that are not authorized, incorrect for the job, defective or damaged could cause serious injury. ● Keep all tools in good condition, learn the correct way to use them.
2-10
Shop Manual - June 2013
CA13082107
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
● Before starting the work, thoroughly check the tools, machine, forklift, crane, service car, etc. ● Keep your tools clean, and when the job is complete, take inventory of the tools you were using to be sure no tools were left in the machine.
A
● Always put shop tools back in there proper storage location when finished.
ZX215-1000033
AM E
RI C
● If welding repairs are needed, always have a trained, experienced or certified welder carry out the work.
2.2.10 Hoisting a Load
TI N
If you will be lifting parts or components that weigh more than 35 lbs (16 kg), it is important to follow some basic rules.
LA
● Always use the appropriate lifting equipment such as hoist, crane, forklift etc. to handle a loads if possible.
NY
● Be sure the lifting equipment is in good condition and rated for the load you are about to lift.
SA
● If straps are to be used, ensure they are in good condition and rated for the load to be lifted with them.
CA13082108
● If you must lift the load by hand, keep your back straight and parallel with the load, and lift the load using your leg muscles to avoid back injuries. Always ask for a lifting assistant.
Shop Manual - June 2013
2-11
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
2.2.11 Appropriate Working Apparel Improper or loose clothing, casual dress clothing, jewelry, incorrect shoes or long hair can result in possible injury.
CA13082109
AM E
RI C
A
Make a list of the types of clothing that are not allowed in the shop area. Go over the list with personnel before they start a job.
2.2.12 Safety Partners
LA
TI N
No one should be allowed to perform work operations in any shop alone. It should be a general shop safety rule for a minimum of two people in the shop area at all times when work procedures are performed. A person alone in the shop might not be able to get emergency help in the event of a shop accident.
NY
When working together always maintain clear contact with each other at all times to avoid the occurrence of unexpected incidents. CA13082110
SA
When carrying out any operation with two or more workers, always agree on the operating procedures and signals before starting.
2-12
Shop Manual - June 2013
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
2.2.13 Two people when engine running In order to prevent injury, do not perform the service while the engine is running. If the service must be performed while the engine is running, operate only when two people are on the spot and follow the regulations below:
RI C
A
● Always have one operator sit on the operation seat and be ready to turn off the engine at any time. All the operators must keep in touch with each other.
● Do not touch any control lever. If some control lever must be operated, send signal to other people and warn them to transfer to safe place quickly.
AM E
● Set the safety lock control lever to the lock position.
2.2.14 Driving Pins
LA
TI N
● Do not drop or insert the tools and other objects into the fan or fan belt, or the parts will be broken or thrown out.
NY
When using a hammer to drive pins, metal particles may fly off. This may lead to serious eye injuries. Always do the following:
SA
● Always wear a face shield or goggles when striking a metal object with a metal hammer. ● Before performing any of these procedures, be sure all personnel are clear of your work area. ● If possible, avoid using a steel hammer to drive a component or pins in place. Damage to the component may result. Always use a soft or non-ferrous hammer to drive a component or a pin.
Shop Manual - June 2013
CZ335-1102069
2-13
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
2.2.15 Aligning Parts or Components ● Be careful when installing or aligning parts or components. ● Avoid using your fingers or hands to position holes or part mating surfaces, serious injury could result if your hand or fingers should get ought between the surfaces.
RI C
A
● Always use tools to align a part or component to avoid any finger or hand injuries.
● It is important to know where all emergency exits and fire extinguishing equipment are located if a fire should occur in the shop.
CA13082111
AM E
2.2.16 Fire Extinguisher and Emergency Exits
LA
TI N
● Before preparing for work, take time and walk around the shop to make a mental note of where all exits and fire equipment are located. If you are performing repairs in the field, always have a fire extinguisher handy and within reach.
CA13082112
NY
● If you do not know how to use a fire extinguisher contact someone who can instruct you in the proper use of this equipment.
SA
2.2.17 Personal Protective Equipment If your shop specifies the use of safety equipment, OSHA requires this equipment to be used when on the shop floor or in the area where this equipment is required. Never allow personnel in the shop area without the proper personnel protective equipment even for a moment. Always keep personnel protective equipment in good condition and replace them as required.
2-14
Shop Manual - June 2013
CZ335-1102002
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
2.2.18 Running the Machine Run the machine during repair procedures ONLY if directed to do so in this shop manual. If the machine must be run when making repairs, it is important to follow some basic safety rules. ● Always be aware of rotating components.
RI C
TI N
● The person in the cab must never touch any controls. If a control lever must be operated, always maintain a clear view to the person doing the repair and signal them when you are about to move the control lever.
CZ335-1102077
AM E
● If equipped, all lock levers must be in the LOCK position or the parking brake must be in the PARK position.
A
● During repair operations while the engine is running, one worker must remain in the operator seat of the machine with clear contact between the person performing the repairs on the machine at all times.
CZ335-1102012
SA
NY
LA
● Be aware of hot surfaces. During running operations, most surfaces will be hot, and some surfaces will be extremely hot. If necessary, use personnel protective equipment when working around high temperature surfaces.
● Keep in mind that during running operations, hydraulic systems, cooling systems and fuel systems will be under extremely high pressure and at high temperatures. ● Always use caution when working on or near these systems.
CA13082113
Shop Manual - June 2013
2-15
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
2.2.19 Accumulator If the machine is equipped with an accumulator charged with high-pressure nitrogen gas, it is important to follow these basic precautions. ● Do not disassemble the accumulator.
A
● Never expose the accumulator to high heat or open flames.
RI C
● Never weld on the accumulator. ● Never drill or cut on the accumulator.
CZ335-1102085
TI N
● Use only nitrogen gas to charge the accumulator. Unapproved gases could be explosive.
AM E
● Never strike the accumulator.
2.2.20 Adding Fluids to a System
LA
If it should be necessary to add fluids to a system during running operations, always be aware that these systems may be hot and under high pressure.
SA
NY
Before adding fluids, shut the machine down and allow the systems to cool down to outdoor ambient temperatures before removing any caps. Failure to do so may result in serious burns or a sudden loss of fluid.
2-16
CA13082114
Shop Manual - June 2013
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
2.2.21 Track Recoil Springs If you are making repairs to a machine equipped with tracks, always be aware of the dangers involved with track recoil springs. This spring is under extreme pressure at all times. If it is disassembled by mistake, the spring may fly out and cause serious injury or death.
2.2.22 High-Pressure Fluid Lines
RI C
CZ335-1102081
AM E
Always stand clear of the track travel path when separating the master link section of the track.
A
Be careful when removing or installing tracks on track-type machines. When removing the master track link the track system may separate suddenly and cause possible injury.
LA
TI N
Always keep in mind that these systems are under high pressure. When inspecting or replacing piping or hoses, always check to be sure the pressure in the system has been relieved before proceeding. Working on a system still under pressure could lead to serious injury, always do as follows:
NY
● If you will be removing a line or component with fluid in the system, always cap and seal the opening to avoid leakage or system contamination.
SA
● Never carry out inspections or replace items while the system is under pressure. ● Never use any part of your body to check or feel for leaks. Always wear safety glasses and leather gloves when checking for leaks and use a piece of wood or cardboard when checking for leaks from small holes. ● If high pressure fluids should penetrate your skin or get into your eyes, seek medical attention immediately.
Shop Manual - June 2013
CZ335-1102082
2-17
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
2.2.23 Safe Work Preparations Before starting any repairs, be sure the machine is sitting on a level stable surface.
RI C
A
Lower all the work equipment to a safe and stable position on the ground. Turn the engine OFF and neutralize the work equipment controls by rotating them to the left and right (joystick control) or moving them back and forth (lever control). This function will relieve system pressure.
If equipped, set the hydraulic lock lever in the LOCKED position. If equipped, set the parking brake in the PARK position.
SA
NY
LA
TI N
Be sure all personnel and equipment is clear of your work area and you can be seen by all working personnel especially if performing repairs in the field.
AM E
Block the tracks (if equipped) or wheels (if equipped) with chocks to prevent the machine from moving.
2-18
Shop Manual - June 2013
CA13082115
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
2.2.24 Mounting and Dismounting It is important to follow these procedures when mounting or dismounting the equipment: ● Use all hand-holds and step plates on your equipment. ● Never jump off or onto the equipment.
RI C
TI N
● When getting on or off the equipment, always face the equipment and maintain a three-point contact (both feet and one hand or one foot and both hands) with the handrails, steps and platforms to ensure that you support yourself correctly.
CA13031506
AM E
● Never get on or off moving equipment. These actions may lead to serious injury. Always bring the equipment to a full stop and turn the engine OFF.
A
● Wipe off any oil, grease, or mud from your shoes, rails, steps or platforms before getting on the equipment; always keep these areas clean and in good condition.
LA
● Never climb on areas of the machine that are not designated walk areas.
NY
● Never climb on or off the machine with tools, parts or similar objects in your hands.
SA
● Never use machine controls or non-specified points on the equipment to get on or off the machine. ● Use all hand-holds when on the machine.
Shop Manual - June 2013
CA13082116
2-19
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
2.2.25 Battery Hazards Working around batteries always poses a hazard, especially if the battery has been in service for a long period of time. Listed below are some basic precautions to be aware of when servicing or working around batteries.
● When working with batteries, always work in a wellventilated area.
RI C
CZ335-1102061
AM E
● Battery gasses are extremely explosive. When opening a battery compartment, always allow ample time for the gasses to escape before servicing the battery.
A
● Always wear personal protective equipment when working around batteries.
CZ335-1102062
NY
LA
TI N
● If the battery is corroded, flush the area with a baking soda and warm water mix.
SA
● If battery acid should get on your skin or in your eyes, flush the area immediately with fresh water and seek medical attention.
CZ335-1102083
2-20
Shop Manual - June 2013
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
2.2.26 Jump-Start Safety When using jumper cables to start the machine, connect the positive (+) jumper first, then the negative (-) jumper to a remote location on the chassis away from the battery.
A
CAUTION
TI N
Before starting any repair operations, remove the battery leads from the battery or set the main disconnect on the machine in the OFF position.
CA13082117
AM E
2.2.27 Disconnecting the System Power
RI C
Never use a welder or a machine with a higher voltage system to jump-start the machine. Doing so may damage the machine’s electrical system or cause an unexpected explosion or fire resulting in minor or major injury.
LA
For the location of the machine main electrical disconnect switch, refer to the machines Safety, Operation & Maintenance Manual for location and procedures.
NY
If the battery must be disconnected, remove the negative (-) terminal clamp first then remove the positive (+) clamp last.
SA
When reconnecting the battery, be sure every electrical system switch is in the OFF position, connect the positive clamp (+) first, then the negative clamp(-) last.
CA13082118
Shop Manual - June 2013
2-21
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
2.2.28 Lockout/tagout
RI C
TI N
Only authorized employees performing repairs on the machine shall perform Lockout/Tagout in accordance with this procedure listed below.
AM E
2.2.29 Sequence of Procedures
A
Due to the size and complexity of this machine, Lockout and Tagout procedures may be required by your company to ensure the safety of yourself and others involved in the repair process of the machine. While work is in progress, all power sources must be disabled, locked and tagged with a warning label. Lockout/Tagout procedure establishes the minimum requirements used to isolate all power sources from potentially hazardous energy, and to ensure that the machine is “locked out and tagged out” before anyone performs repairs on the machine.
LA
If the employee performing repairs to the machine is issued
NG
ER DO OP NO ER T AT E
NY
a lock and key, the employee shall not share the lock or key with other employees until all repair procedures are complete and the machine is ready to put back into service.
DA
SA
The following steps shall be performed in the sequence listed when the equipment is to be either locked-out or tagged-out for repair.
2-22
CA13082119
Shop Manual - June 2013
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
Locking out of service 1. Notify all employees who may be potentially affected by the repair process on the machine.
DANGER
2. Secure the machine in a safe position. If equipped, set the parking brake or hydraulic lock lever in the PARK or LOCKED position.
A
RI C
CA13082120
TI N
4. Be sure all employees involved in the repairs have installed there lock on the power source before performing any repairs. Once an employee has completed there repair procedure, they must remove there lock and not access the machine in any manor.
When this is not being used, keep it in the storage compartment.
AM E
3. Identify, remove or disconnect all power or energy sources and be sure to install a Lockout/Tagout device on them. If the machine is equipped with a Maintenance Alert Tag, attach this tag to the machine controls.
DO NOT OPERATE
LA
Returning to service
NY
1. The authorized person who performed the Lock out/Tagout procedure shall check the area around the machine to ensure that no one is exposed to any hazard before startup.
SA
2. The authorized person who performed the Lock out/Tagout shall ensure that all guards have been reinstalled to their proper place, all tools and equipment have been removed and all locks are removed. 3. The authorized person who performed the Lock out/Tagout shall verify that all controls are in the neutral or “off” position and all personnel are aware of the time the machine will be back in service.
Shop Manual - June 2013
2-23
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
4. Remove the Lockout/Tagout equipment and any additional alert equipment and reenergize the machine for return to service.
RI C
TI N
2.2.31 Material Safety Data Sheets (MSDS)
AM E
Exposure to hazardous chemicals pose a serious danger if released or mishandled. Handling hazardous materials often releases substances that could pose a hazard. Temporary implication or possible residual injury may result unless proper precautions are observed while working with these materials. All workers involved in handling hazardous materials should use approved personal protective equipment and follow all environmental safety regulations.
A
2.2.30 Chemical hazard
Material Safety Data Sheet (MSDS) information relating to the materials the workers could be exposed to.
NY
LA
● MSDS data sheets provide both workers and emergency personnel with the proper procedures for handling or working with a particular substance. Information includes physical data, health effects, first aid, reactivity, storage, disposal and protective equipment required.
SA
● Be sure all personnel involved are familiar with all MSDS-related information as it relates to the hazardous materials they could be exposed to. Keep MSDS data sheets handy in site of all employees and emergency personnel where they can be easily accessed. ● Never handle hazardous materials without the proper MSDS information. Always verify the data on the MSDS sheet before handling any hazardous materials.
2-24
Shop Manual - June 2013
CA13082121
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
2.3 Precautions for sling work and giving signals
RI C
A
1. Only one appointed worker is allowed to give signals and co-workers must communicate with each other frequently. The appointed signal person must give specified signals clearly at a place where he is seen well from the operator's seat and where he can see the working condition easily. The signal person must always stand in front of the load and guide the operator safely. ● Do not stand under the load.
2. Check the slings before starting sling work. 3. Always wear gloves during sling work. (Wear leather gloves, if available.)
AM E
● Do not step on the load.
TI N
4. Measure the weight of the load by the eye and check its center of gravity.
LA
5. Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall.
NY
6. Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically.
SA
7. Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook.
Shop Manual - June 2013
2-25
Shop Safety
19.6 2000
kN kg 18.6 1900
16.7 1700
13.7 1400
9.8 1000
30
60
90
4.9 500
A
9.8 1000
120
150
RI C
Hanging angle (Deg.)
ZX215-1000001
TI N
8. When installing wire ropes to an angular load, apply softeners to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping.
19.6 2000
AM E
When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.
Load capacity kN(kg)
SY195/205/215/225C9 Crawler Hydraulic Excavator
9. Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc.
LA
10. Apply wire ropes to the middle portion of the hook.
NY
● Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
SA
11. Do not use twisted or kinked wire ropes. 12. When lifting up a load, observe the following.
100%
88%
79%
71%
41%
ZX215-1000002
2-26
Shop Manual - June 2013
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
● Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught.
RI C
A
● After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and softener.
● Do not lift up the load slantingly. 13. When lowering a load, observe the following.
TI N
● When lowering a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
AM E
● If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.
● Check that the load is stable, and then remove the sling.
SA
NY
LA
● Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
Shop Manual - June 2013
2-27
Shop Safety
SY195/205/215/225C9 Crawler Hydraulic Excavator
Selecting wire ropes Select adequate ropes as per the weight of parts to be hoisted, referring to the table below. Wire ropes (Standard “Z” twist ropes without galvanizing) Nominal Diameter of Rope
Allowable Load kN
Ton
10
9.8
1.0
11.5
13.7
1.4
12.5
15.7
14
21.6
16
27.5
18
35.5
20
43.1
22.4
54.9
30
98.1
40
176.5
18.0
274.6
28.0
392.2
40.0
RI C
A
mm
1.6 2.2
TI N
AM E
2.8
50
LA
60
CAUTION
SA
NY
● The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
2-28
Shop Manual - June 2013
3.6 4.4 5.6 10.0
Shop Safety
SA
BLNY ANLA TI KN PAAM E G RI E CA
SY195/205/215/225C9 Crawler Hydraulic Excavator
Shop Manual - June 2013
2-29
SY195/205/215/225C9 Crawler Hydraulic Excavator
BSLAN AYNL AT K IN PAA M GERI E CA
Shop Safety
2-30
Shop Manual - June 2013
RI C
Specifications 3 Specifications
TI N
AM E
Dimensions .............................................................................................................. 3-3 Working Ranges ...................................................................................................... 3-4 Technical Specifications........................................................................................... 3-5 Weight Table ............................................................................................................ 3-8 Recommended Oil, Fuel and Coolant...................................................................... 3-9 Capacity Table ....................................................................................................... 3-10 Engine Performance Curve ....................................................................................3-11
SA
NY
LA
3.1 3.2 3.3 3.4 3.5 3.6 3.7
A
Specifications
SY195/205/215/225C9 Crawler Hydraulic Excavator
Shop Manual - June 2013
3-1
Specifications
SA
NY
LA
TI N
AM E
RI C
A
SY195/205/215/225C9 Crawler Hydraulic Excavator
3-2
WARNING
Read and understand all safety precautions and instructions in this manual before reading any other manuals provided with this machine and before operating or servicing the machine. Also read the safety information on machine decals before performing any operations. Failure to do so can cause machine damage, personal injury or death.
Shop Manual - June 2013
Specifications
SY195/205/215/225C9 Crawler Hydraulic Excavator
3 SPECIFICATIONS 3.1 Dimensions
A D
RI C
A
I
C
E
G
AM E
H F
Item
TI N
B
L
J K
CJ13032601-1
Unit: mm (ft, in)
SY195C-9
SY205C-9
SY215C-9
SY225C-9
Overall length (shipping)
9560 {31'4''}
9680 {31'9''}
9680 {31'9''}
9680 {31'9''}
B
Overall width
2800 {9'2''}
2800 {9'2''}
2980 {9'9''}
2980 {9'9''}
C
Overall height (Shipping)
3250 {10'8''}
3440 {11'3''}
3440 {11'3''}
3440 {11'3''}
D
Width (top)
2710 {8'11''}
2710 {8'11''}
2710 {8'11''}
2710 {8'11''}
E
Overall height (to cab roof)
2990 {9'10''}
2990 {9'10''}
2990 {9'10''}
2990 {9'10''}
F
Std. track shoe width
600 {1'12''}
600 {1'12''}
600 {1'12''}
600 {1'12''}
G
Track gauge
2200 {7'3''}
2200 {7'3''}
2380 {7'10''}
2380 {7'10''}
H
Min. ground clearance
440 {1'5''}
440 {1'5''}
440 {1'5''}
440 {1'5''}
Tail swing radius
2890 {9'6''}
2890 {9'6''}
2890 {9'6''}
2890 {9'6''}
J
SA
NY
LA
A
Length of track on ground
3260 {10'8''}
3355 {11'0''}
3445 {11'4''}
3640 {11'11''}
K
Track length
4060 {13'4''}
4160 {13'8''}
4250 {13'11''}
4445 {14'7''}
I
Shop Manual - June 2013
3-3
Specifications
SY195/205/215/225C9 Crawler Hydraulic Excavator
3.2 Working Ranges
RI C
A
f
a g
TI N
AM E
b
e
LA
d
SA
NY
c
SY195C-9
a
Max. cutting height
9410 {30'10''}
9570 {31'5''}
9570 {31'5''}
9570 {31'5''}
b
Max. dumping height
6490 {21'4''}
6700 {21'12''}
6700 {21'12''}
6700 {21'12''}
c
Max. digging depth
6410 {21'0''}
6600 {21'8''}
6600 {21'8''}
6600 {21'8''}
d
Max. vertical digging depth
5790 {18'12''}
5800 {19'0''}
5800 {19'0''}
5800 {19'0''}
e
Max. digging reach
9740 {31'11''}
9950 {32'8''}
9950 {32'8''}
9950 {32'8''}
f
Min. swing radius
3755 {12'4''}
3595 {12'12''}
3595 {12'12''}
3595 {12'12''}
g
Max. height at min. swing radius
7700 {25'3''}
7665 {25'2''}
7665 {25'2''}
7665 {25'2''}
Item
3-4
CJ13032602-1
Unit: mm (ft, in) SY205C-9
SY215C-9
SY225C-9
Shop Manual - June 2013
Specifications
SY195/205/215/225C9 Crawler Hydraulic Excavator
3.3 Technical Specifications
m³
0.8
0.8
0.9
1.0
kg kN kN rpm km/h Deg. kPa
21000 135 109 11 5.4/3.3 35 47
mm L KW/rpm
LA
NY
Type Max. delivery Safety valve pressure Type x No. Control method
SA
Hydraulic Control Hydraumotor valve lic pump
Track shoe (each side)
SY225C-9
Travel motor Swing motor
Type Bore Rod diameter Stroke Hydraulic tank Hydraulic oil filter element Hydraulic oil cooler
A
21200 21800 22600 138 138 138 103 103 103 11 11 11 5.4/3.3 5.4/3.3 5.4/3.3 35 35 35 46 47 46 MITSUBISHI 6D34-TL 6-cylinder, 4-cycle, water-cooled, in-line, direct injection 6-Φ104mm×115mm 5.86 114 / 2050
N·m/rpm rpm rpm g/KWh
Carrier roller (each side) Track roller (each side)
SY215C-9
590 / 1400 2200±50 1000±10 210 24V/5.0 KW 24V/50A
TI N
Max. torque Max. speed at no load Min. speed at no load Min. fuel consumption Starting motor Alternator
Hydraulic cylinder
Hydraulic system
Undercarriage
Engine
Performance
Operating weight Max. bucket digging force Max. arm digging force Swing speed Travel speed (Hi/Lo) Gradeability Ground pressure Model Type No. of cylinders-bore x stroke Piston displacement Rated power
SY205C-9
RI C
Bucket capacity
SY195C-9
AM E
Machine model
L/min Mpa
2
2
2
2
7
7
8
9
45
46
47
49
KAWASAKI (Variable displacement piston type) 2×210 34.3 KMX15RB/B45201B ×1 Hydraulic 2 x KYB variable displacement piston type (with brake valve and parking brake) 1 x KAWASAKI angle type, piston type (swing brake controller) Double acting piston 120 (Boom), 135 (Arm), 115 (Bucket) 85 (Boom), 95 (Arm), 80 (Bucket) 1285 (Boom), 1490 (Arm), 1120 (Bucket) Closed type Tank return side Air-cooling type
Shop Manual - June 2013
3-5
Specifications
SY195/205/215/225C9 Crawler Hydraulic Excavator
Engine Item
Specification
Engine model
6D34TLE2A
Type
In-line 6-cylinder; water-cooled, 4-cycle diesel engine
Combustion chamber type
Direct injection OHV kW{PS}/rpm
114{155}/2050
Max. torque
N·m{kgf·m}/rpm
590{60}/1400
Bore×Stroke
mm
φ104×115
cm³{L}
5860{5.860}
AM E
Total displacement Compression ratio
18.2
Swing motor
KAWASAKI
Model Type
TI N
Producer
cm³/rev
Safety valve set pressure
MPa {Kg/cm³}
Rated engine speed
2050
MPa {Kg/cm³}
3.4 {34}
Item
Specification KMX15RB
SA
Model
Standard flow rate (equivalent to one pump) Maximum pressure Maximum pressure
25.5 {260}
rpm
NY
Brake release pressure
M5×180CHB-12A-51A/260 angle type, piston type (swing brake controller) 129.2
LA
Theoretical displacement
Control valve
RI C
Max. output power
300 L/min
When main relief valve is normal
34.3 MPa
When main relief valve is boosting
37.3 MPa
When port relief valve is normal
39.2 MPa
Working oil temperature
-20~90°C
Drained oil maximum pressure
0.3 MPa
3-6
A
Valve mechanism
Shop Manual - June 2013
Specifications
SY195/205/215/225C9 Crawler Hydraulic Excavator
Travel motor Maker
KYB
Model
kg
MAG-170VP-3400E Variable displacement piston type (w/ brake valve and parking brake) 275
cm³/rev
qxi
Large displacement q1
cm³/rev
130.4
Small displacement q2
cm³/rev
74.9
Equivalent displacement Motor displacement q
RI C
Weight
A
Type
Speed reduction rate i 2-speed switching Pilot pressure
60
Lo-Hi
Mpa
Hi-Lo
Mpa
> 1.96
N·m
398
L/min
228
Operating pressure
Mpa
33.34
Peak pressure
Mpa
within 44.1
Acting times (above 34.3Mpa and below 44.1Mpa)
times
< 1,200,000
Large flow
rpm
1679
Small flow
rpm
2861
Large flow
rpm
28
Small flow
rpm
47.7
KN·m
within 37
Motor shaft Swing speed
Output torque Input power
Normal
PS
Maximum
PS
within 210 (within 30 consecutive sec.)
Normal
Mpa
within 0.2
Momentary maximum
Mpa
within 0.5 (below 0.3 MHz)
SA
NY
Drain pressure
LA
Reducer
TI N
Operating displacement
AM E
Braking torque
> 6.86
Shop Manual - June 2013
3-7
Specifications
SY195/205/215/225C9 Crawler Hydraulic Excavator
3.4 Weight Table Unit: kg SY205C-9
SY215C-9
SY225C-9
Engine
520
520
520
520
Radiator assembly
80
80
80
80
Hydraulic tank assembly (w/o hydraulic oil)
148
148
148
148
Fuel tank assembly (w/o fuel)
126
126
126
126
Revolving frame
1770
1770
1770
Operator cab
360
360
Operator seat & control console
75
75
Counterweight
3900
3900
Hydraulic pump
120
120
Control valve
185
Swing reducer assembly
200
A
SY195C-9
RI C
Machine Model
1770 360
75
75
3900
3900
120
120
185
185
185
200
200
200
300×2
300×2
300×2
56
56
56
2280
2432
2746
2746
286 116×2 135×2 25.5×4 40×14
286 116×2 135×2 25.5×4 40×14
286 116×2 135×2 25.5×4 40×16
286 116×2 135×2 25.5×4 40×18
1568
1568
1590
1590
706
709
709
709
769
769
781
781
206×2
206×2
206×2
206×2
262
262
262
262
Bucket cylinder assembly
188
188
188
188
Linkage
68
68
68
68
Rocker
22×2
22×2
22×2
22×2
Final drive assembly
300×2
Center swivel joint
56
Boom assembly Arm assembly
NY
Bucket assembly
LA
Swing bearing Idler Tensioning device Carrier roller Track roller
TI N
Track frame
Boom cylinder assembly
SA
Arm cylinder assembly
3-8
AM E
360
Shop Manual - June 2013
Specifications
SY195/205/215/225C9 Crawler Hydraulic Excavator
3.5 Recommended Oil, Fuel and Coolant
Reservoir
Fluid type
-22 -30
-4 -20
14 -10
Ambient temperature 32 50 68 0 10 20
86 30
104 40
122°F 50°C
SAE 10W Engine oil pan
RI C
SAE 10W-30
A
SAE 30
SAE 15W-40
AM E
Swing machinery Engine oil
case Idler
SAE 30
Track roller
LA
TI N
Carrier roller
Hydraulic system
SAE 10W SAE 10W-30 SAE 15W-40
L-HV32 Low-temp, wear-resistant hydraulic oil
NY
Hydraulic L-HM46 Wear-resistant hydraulic oil L-HM68 Wear-resistant hydra. oil
SA
oil
Fuel tank
Diesel fuel
ASTM D 975 No.2 GB252 Super-20 Diesel fuel GB252 Super-35 Diesel fuel
Grease fitting
Grease
Cooling system
Coolant
NLGI No.2 TEEC L35
Shop Manual - June 2013
3-9
Specifications
SY195/205/215/225C9 Crawler Hydraulic Excavator
● Machine oil above API CF-4 (no lower than APC CD) is recommended. ● Gear oil GL-5 is recommended. ● Obtain genuine oil from Sany Heavy Machine or its authorized dealers.
3.6 Capacity Table Final drive casing 5.5 {1.45}
Hydraulic system 239 {63.14}
Cooling system 22.5 {5.94}
SA
NY
LA
TI N
AM E
22 {5.81}
Swing mechanism casing 4.0 {1.06}
3-10
Shop Manual - June 2013
Fuel tank
340 {89.82}
RI C
Engine oil pan
A
Unit: L {US Gal}
Specifications
SY195/205/215/225C9 Crawler Hydraulic Excavator
3.7 Engine Performance Curve Testing condition: 1) Temperature: 298K, one standard atmospheric pressure. 2) No fan.
N·m Torque
RI C
500 400
Torque
A
600
300
AM E
kW 120
Power output
TI N
80
LA
Power output
100
NY
60
SA
40
240
20
Fuel consumption
230 220
Fuel consumption
g/kw·h
210
1000
1200
1400
1600
Engine speed min
1800
2000
-1
Shop Manual - June 2013
ZX215-1001003
3-11
SY195/205/215/225C9 Crawler Hydraulic Excavator
BSLAN AYNL AT K IN PAA ME G RI E CA
Specifications
3-12
Shop Manual - June 2013
Structure and Function
A
SY195/205/215/225C9 Crawler Hydraulic Excavator
RI C
Structure and Function 4 Structure and Function
SA
NY
LA
TI N
AM E
4.1 Engine and Cooling System .................................................................................... 4-5 4.1.1 Engine-related parts....................................................................................... 4-5 4.1.2 Radiator and intercooler................................................................................. 4-6 4.2 Power Train.............................................................................................................. 4-7 4.2.1 Power transmission system .......................................................................... 4-7 4.2.2 Final drive assembly ...................................................................................... 4-8 4.2.3 Swing machinery.......................................................................................... 4-12 4.2.4 Swing bearing .............................................................................................. 4-14 4.3 Undercarriage and Frame...................................................................................... 4-15 4.3.1 Track frame and recoil spring....................................................................... 4-15 4.3.2 Idler .............................................................................................................. 4-17 4.3.3 Carrier roller ................................................................................................. 4-19 4.3.4 Track roller ................................................................................................... 4-20 4.3.5 Track shoe ................................................................................................... 4-21 4.3.6 Triple grouser shoe ...................................................................................... 4-25 4.4 Hydraulic System, Part 1 ....................................................................................... 4-26 4.4.1 Hydraulic equipment layout.......................................................................... 4-26 4.4.2 Hydraulic tank and filter ............................................................................... 4-28 4.4.3 Hydraulic pump ................................................................................................... 4-29 4.4.4 Pilot pump .................................................................................................... 4-36 4.4.5 Regulator .................................................................................................... 4-37 4.4.5.1 Control mechanism makeup ............................................................... 4-39 4.4.5.2 Adjustment of the regulator ................................................................. 4-40 4.4.5.3 Operation ............................................................................................ 4-42 4.5 Hydraulic System, Part 2 ....................................................................................... 4-45 4.5.1 Control valve ................................................................................................ 4-45 Shop Manual - June 2013
4-1
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
SA
NY
LA
TI N
AM E
RI C
A
4.5.2 Operating principle ....................................................................................... 4-48 4.5.2.1 When spool is in neutral position ........................................................ 4-48 4.5.2.2 Travel .................................................................................................. 4-50 4.5.2.3 Arm...................................................................................................... 4-51 4.5.2.4 Boom................................................................................................... 4-56 4.5.2.5 Bucket ................................................................................................. 4-59 4.5.2.6 Swing .................................................................................................. 4-61 4.5.2.7 Option ................................................................................................. 4-63 4.5.2.8 Travel straight ..................................................................................... 4-64 4.5.2.9 Lock valve function ............................................................................. 4-65 4.5.2.10 Main relief valve function .................................................................. 4-67 4.5.2.11 Port relief valve function .................................................................... 4-68 4.5.3 Section view ................................................................................................. 4-72 4.6 Hydraulic System, Part 3 ....................................................................................... 4-83 4.6.1 Swing motor ................................................................................................. 4-83 4.6.2 Swing holding brake..................................................................................... 4-85 4.6.3 Relief valve portion ...................................................................................... 4-86 4.6.4 Reverse prevention valve ............................................................................ 4-88 4.6.4.1 Operation drawing............................................................................... 4-88 4.6.4.2 Explanatory drawing of effects ............................................................ 4-89 4.6.5 Center swivel joint ........................................................................................ 4-91 4.6.6 Travel motor ................................................................................................. 4-93 4.6.6.1 Operation of components.................................................................... 4-95 4.6.7 Valve control system .................................................................................. 4-107 4.6.8 Pilot valve.................................................................................................. 4-109 4.6.8.1 Work equipment and swing pilot valve.............................................. 4-109 4.6.8.2 Travel PPC valve ...............................................................................4-113 4.6.9 Solenoid valve.............................................................................................4-117 4.6.10 Accumulator ..............................................................................................4-118 4.6.11 Pilot oil filter ...............................................................................................4-119 4.6.12 Pump oil pressure sensor ........................................................................ 4-120 4.6.13 Hydraulic cylinder..................................................................................... 4-121 4.6.14 Work equipment ....................................................................................... 4-123 4.7 Air Conditioning System....................................................................................... 4-129 4.7.1 A/C components layout drawing ................................................................ 4-130 4.7.2 Control panel.............................................................................................. 4-131 4.7.3 Circuit diagram ........................................................................................... 4-132 4.7.4 Refrigeration principle ................................................................................ 4-134
4-2
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
SA
NY
LA
TI N
AM E
RI C
A
4.7.4.1 Refrigeration cycle diagram .............................................................. 4-134 4.7.4.2 Heating cycle diagram ...................................................................... 4-134 4.7.5 Compressor ............................................................................................... 4-135 4.7.6 Clutch ......................................................................................................... 4-137 4.7.8 Condenser ................................................................................................. 4-138 4.7.7 Expansion valve ......................................................................................... 4-138 4.7.9 Evaporator ................................................................................................. 4-139 4.7.10 Receiver tank ........................................................................................... 4-139 4.7.11 Pressure switch ........................................................................................ 4-140 4.7.12 Fresh air sensor ....................................................................................... 4-141 4.7.13 Refrigerant ............................................................................................... 4-141 4.7.14 Compressor oil ......................................................................................... 4-160 4.8 Engine Control ..................................................................................................... 4-161 4.8.1 System operation ...................................................................................... 4-162 4.8.2 Components............................................................................................... 4-163 4.8.2.1 Fuel control dial................................................................................. 4-163 4.8.2.2 Controller .......................................................................................... 4-165 4.9 Electrical Control System..................................................................................... 4-167 4.9.1 Control function .......................................................................................... 4-167 4.9.2 Machine control system diagram ............................................................... 4-168 4.9.3 Engine and pump composite control function ............................................ 4-170 4.9.4 Pump control function ................................................................................ 4-174 4.9.4.1 Electrical positive flow control ........................................................... 4-175 4.9.4.2 Constant power control ..................................................................... 4-178 4.9.5 Valve control function ................................................................................. 4-180 4.9.5.1 Bucket flow control ............................................................................ 4-181 4.9.5.2 Swing priority control......................................................................... 4-182 4.9.6 Duo travel speed control ............................................................................ 4-183 4.9.7 Engine preheating/overheating alarm ....................................................... 4-185 4.9.7.1 Engine preheating ............................................................................. 4-186 4.9.7.2 Engine overheating alarm ................................................................. 4-187 4.9.8 Engine oil under–pressure alarm ............................................................... 4-187 4.9.9 Auto deceleration/acceleration control ....................................................... 4-188 4.9.10 Engine speed calibration function ............................................................ 4-190 4.9.11 Electrical Components ............................................................................. 4-192 4.9.11.1 Pump pressure sensor .................................................................... 4-192 4.9.11.2 Pilot pressure sensor ...................................................................... 4-193 4.9.11.3 Engine speed sensor ...................................................................... 4-194
Shop Manual - June 2013
4-3
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
SA
NY
LA
TI N
AM E
RI C
A
4.9.11.4 Coolant temperature sensor............................................................ 4-195 4.9.11.5 Fuel level sensor ............................................................................. 4-196 4.9.11.6 Oil pressure switch .......................................................................... 4-197 4.10 Monitoring System ............................................................................................. 4-198 4.10.1 Machine monitor ...................................................................................... 4-199 4.10.2 Monitor functions...................................................................................... 4-200 4.10.3 Monitor operation ..................................................................................... 4-203
4-4
WARNING
Read and understand all safety precautions and instructions in this manual before reading any other manuals provided with this machine and before operating or servicing the machine. Also read the safety information on machine decals before performing any operations. Failure to do so can cause machine damage, personal injury or death.
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4 STRUCTURE AND FUNCTION 4.1 Engine and Cooling System
LA
TI N
AM E
RI C
A
4.1.1 Engine-related parts
Fan
3)
SA
1)
2
NY
1
4)
Start motor
5)
Rubber damper assembly
6)
Rear engine mount
7)
Muffler
2)
Front engine mount Fuel filter
3
4
5
6
7 ZX215-1002001
Specification Oil capacity: 22 L
Shop Manual - June 2013
4-5
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.1.2 Radiator and intercooler
2
3
1
A
4
RI C
5
6
AM E
7
TI N
8
LA
9
WX215-1204009G
Radiator outlet hose
2)
Radiator inlet hose
3)
Radiator
4)
Intercooler air intake
5)
Reserve tank
Aluminum pipe, belt-type radiator
6)
Intercooler
7)
Intercooler air outlet
8)
Fan guard
Radiator and oil cooler in parallel connection; intercooler in series connection with radiator and oil cooler.
9)
Radiator cap
SA
NY
1)
Specifications Radiator assembly: ZH860×385×1050-S70Y75Z20Q/SY015
Reservoir capacity: 8.9 L (2.35 US gal) Engine coolant capacity: 9.5L (2.51 US gal)
4-6
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.2 Power Train 4.2.1 Power transmission system 2
1
5
6
7
8
9
10
SA
NY
LA
4
TI N
AM E
RI C
A
3
ZX215-1002003
1)
Swing motor
6)
Accumulator
2)
Swing reducer
7)
Control valve
3)
Swing bearing
8)
Final drive AS
4)
Idler
9)
Hydraulic pump
5)
Central swivel joint
10) Engine
Shop Manual - June 2013
4-7
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.2.2 Final drive assembly Final drive AS (KYB)
1
3
2
4
19
17
73±3.6 N·m
205±10 N·m
RI C
A
5
AM E
59±4.9 N·m
18
TI N 11
8
157±8 N·m 16
NY
6 7
LA
12
20
10
9 ZX215-1002004-1
SA
13
14
15 ZX215-1002005
4-8
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
1)
Cylinder GP
9)
2)
Shaft
10) No. 2 planetary gear (No. of teeth: 36)
3)
Gear hub (No. of teeth: 85)
11) Seal ring
4)
No. 2 planetary carrier
12) Travel motor
5)
No. 1 planetary carrier
13) Fill port
6)
No. 1 planetary gear (No. of teeth: 36)
14) Level port
7)
No. 1 sun gear (No. of teeth: 12)
15) Drain port
8)
End cover
A
No. 2 sun gear (No. of teeth: 19)
RI C
Specifications Reduction ratio:
No.
AM E
( (12+85) /12) × ( (19+85) /19) ) -1= 43.246
Criteria
Check item
Standard clearance
Clearance limit
0.13 – 0.47
1.00
Backlash between No. 2 sun gear and No.2 planetary gear
17
Backlash between No. 1 planetary gear and gear hub
0.17 – 0.57
1.10
18
Backlash between No. 1 sun gear and No.1 planetary gear
0.14 – 0.46
1.00
Backlash between No. 2 planetary gear and gear hub
Backlash between No. 1 planetary carrier and No. 2 sun gear
Replace
Replace
0.16 – 0.56
1.10
0.38 – 0.66
1.00
SA
NY
20
LA
19
TI N
16
Remedy
Shop Manual - June 2013
4-9
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Final drive AS (Daewoo)
22
A
6
25 26
14 15
3 9 13 12 8
27
TI N
30
5
18
27
17
1 32
20
19
7
16
WX215-1204010G
13) Planetary gear shaft
25) Seal ring
14) Sun gear
26) O-ring
15) Snap ring
27) Thrust washer
16) Planetary gear
28) Thrust washer
17) Needle bearing
29) Thrust plate
18) Drive gear
30) Gear carrier
Planetary gear shaft
19) Spring pin
31) Gasket
8)
Planetary gear
20) End cover
32) O-ring
9)
Thrust washer
21) Socket head bolt
33) O-ring
10) Spring pin
22) Radial thrust ball bearing
34) Fill port
11) Needle bearing
23) O-ring
35) Level port
12) Floating bush
24) Plug
36) Drain port
O-ring
2)
Mandrel
3)
Float seal
4)
Gear carrier
5)
Hub
6)
Spacer
7)
4-10
SA
NY
LA
1)
21
28
11
9 31
24
29
4 10
2
AM E
23
33
RI C
22 3
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.2.3 Swing machinery
9
A
20 19
RI C
8 7
AM E
59~74 Nm
6 5
21 22 10 23 24 11
LA
3
TI N
4
12 25 26 13 27
NY
2 1
SA
14 15
16 17 18 28 ZX215-1002007
Shop Manual - June 2013
4-11
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Plug
11) No. 2 planetary gear GP
2)
Oil seal
12) No. 2 planetary gear (No. of teeth:17)
3)
Self-aligning bearing
13) Spring pin
4)
Ring gear (No. of teeth:52)
14) Swing reducer screw plug
5)
No. 2 planetary carrier
15) Grease fitting
6)
No. 1 planetary carrier
16) Self-aligning bearing
7)
No. 2 sun gear (No. of teeth: 16)
17) Bearing sealing
8)
No. 1 sun gear (No. of teeth:14)
18) Swing pinion
9)
Swing motor
19) Dipstick 20) Oil filling pipe
RI C
10) No. 1 planetary gear (No. of teeth:18) Specifications
AM E
Reduction ratio: (14+25) /14× (16+25) /14= 20.04
22
Standard clearance
Clearance limit
0.18 – 0.28
—
0.16 – 0.50
1.00
TI N
21
Criteria
Check item Backlash between swing motor shaft and No. 1 sun gear Backlash between No. 1 sun gear and No.1 planetary gear
LA
No.
A
1)
Backlash between No. 1 planetary gear and ring gear
0.18 – 0.59
1.10
24
Backlash between No. 1 planetary carrier and No. 2 sun gear
0.39 – 0.71
1.20
25
Backlash between No. 2 sun gear and No.2 planetary gear
0.16 – 0.50
0.90
Backlash between No. 2 planetary gear and ring gear
0.18 – 0.59
1.00
27
Backlash between No. 2 planetary carrier and swing pinion
0.07 – 0.23
—
28
Backlash between swing pinion and swing bearing
0.22 – 1.32
2.00
4-12
SA
26
NY
23
Shop Manual - June 2013
Unit: mm Remedy Replace
Replace
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.2.4 Swing bearing b
a
A
A
RI C
A
AM E
1
2
LA
TI N
3
549±50 Nm
549±50 Nm
2) 3)
ZX215-1002008
Swing bearing inner race (Teeth: 91)
Specifications
SA
1)
NY
A-A
Ball
Reduction ratio: 91/13= 7
Swing bearing outer race
Amount of filled grease: 13±1 Kg
a. Inner race soft zone S position b. Outer race soft zone S position
Unit: mm
Check item Axial clearance of bearing (when mounted on chassis)
Criteria
Remedy
Standard clearance
Clearance limit
0.5~1.6
3.2
Shop Manual - June 2013
Replace
4-13
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.3 Undercarriage and Frame 4.3.1 Track frame and recoil spring
2
3
4
AM E
RI C
A
1
7
5
10
9
LA
11
6
TI N
8
X
SA
NY
X
1)
Idler
2)
Track frame
3)
Carrier roller
4)
Sprocket
5)
Track roller
6)
Track shoe
7)
Center guard
8)
Front guard
4-14
ZX215-1002009
● Dimension and number of track rollers may vary depending on the machine model, but the basic structure is the same. Model
Q'ty (One side)
SY195C9
7
SY205C9
7
SY215C9
8
SY225C9
9
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Standard track shoe Model
SY195C9
SY205C9
SY215C9
SY225C9
600
600
600
600
Link pitch(mm)
190
190
190
190
Q'ty (One side)
45
46
47
49
Check item
9
Vertical width of idler guide
10
Criteria
Standard size Tolerance
Horizontal width of idler guide
107
—
—
Idler support
105
—
—
Track frame
250
—
—
Idler support
247
—
—
Standard size
Recoil spring
466
Build-up welding or replace
Installation load
Free length
Installation load
157.9 kN {16112 kg}
545
133.9 kN
Replace
SA
NY
LA
598 x 247
Remedy
Repair limit
TI N
11
Free length Installation x Outside length diameter
Unit: mm
Repair limit
Track frame
AM E
No.
RI C
A
Item Shoe width(mm)
Shop Manual - June 2013
4-15
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.3.2 Idler
5 6 4
A
3
8
2
SA
NY
LA
TI N
1
AM E
157~255 Nm
RI C
7
W13081901
4-16
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Unit: mm Check item
Criteria
1
Outside diameter of protrusion
2
Remedy Repair limit
560
—
Outside diameter of tread
520
508
3
Thickness of tread
30
24
4
Difference of tread
20
26
5
Total width
164
—
6
Width of tread
39.5
—
7
Diameter of shaft
8
Clearance between bushing and support (Sum of clearance at both sides)
65
—
Clearance limit
Replace
—
SA
NY
LA
TI N
AM E
Standard clearance 0.5~1.0
Build-up welding or replace
RI C
Standard size
A
No.
Shop Manual - June 2013
4-17
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.3.3 Carrier roller
3
A
5
AM E
RI C
8
7
2
1
No.
Check item
LA
TI N
6
4
ZX215-1002011
Unit: mm
Criteria
Remedy
Standard size
Repair limit
165
—
Outside diameter of tread
140
130
3
Width of tread
44
—
4
Thickness of tread
41.5
34
5
Width of flange
18
—
6
Clearance between shaft and bushing
Outside diameter of flange
2
7
8
4-18
SA
NY
1
Interference between roller and bushing Axial clearance of roller
Tolerance
Standard size
Shaft
50
—
Hole
Standard clearance
Clearance limit
—
—
—
Tolerance
Standard size
Shaft
Hole
57
—
—
Standard Interferinterference ence limit —
—
Standard clearance
Clearance limit
0.44 – 0.76
—
Shop Manual - June 2013
Replace
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.3.4 Track roller 9
A
3
8
1
RI C
2
AM E
549±59 Nm
7
5
6
Check item
LA
No.
TI N
4 W13081902
Unit: mm Criteria
Remedy
Standard clearance
Repair limit
193
—
160
148
Thickness of tread
46.5
40.5
4
Total width
237
—
5
Width of tread
46.5
—
6
Width of flange
32
—
7
Inside width
80
8
Diameter of shaft
65
—
9
Clearance between bushing and collar
Standard clearance
Clearance limit
0.5 – 1.0
—
Outside diameter of flange
2
Outside diameter of tread
3
SA
NY
1
Shop Manual - June 2013
Build-up welding or replace
Replace
4-19
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.3.5 Track shoe
A
1
AM E
RI C
4
19
21 15
23
TI N
7
11
12
20
LA
10
24
22
SA
9
4-20
5 14
2
3
8
13
NY
6
17
16
18
Shop Manual - June 2013
W13100801
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Unit: mm Criteria
Link pitch
2
Outside diameter of bushing
3
Thickness of bushing metal
4
Link height
Standard size
Repair limit
190
193
Standard size
Repair limit
59.45
53.7
10.75
5.75
Standard size
Repair limit
105
98
5 6
Shoe bolt pitch
69 Link
Overall width Tread width Regular
12
Protrusion of bushing
13
Overall length of pin
14
Overall length of bushing
15
Thickness of spacer
NY
38
2.7
Master
2.7
Regular
3.7
Master
0.0
Regular
207
Master
209
Regular
136
Master
128.5
Adjust or replace
—
Bushing
88.2 – 245 kN {9 – 25 ton}
Regular pin
127.4 – 274.4 kN {13 – 28 ton}
Master pin
78.4 – 147 kN {8 – 15 ton}
—
SA
18
Press-fitting force
40
TI N
Protrusion of pin
LA
11
82.57
AM E
Inside width
10
17
Repair or replace
119.57
8
16
Reverse or replace
155.57
7 9
Remedy
A
1
Check item
RI C
No.
Shop Manual - June 2013
4-21
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Unit: mm Check item
Criteria Tightening torque (Nm {kgm})
b. Master link
21
22
23
59.45
Interference between regular pin and link Clearance between regular pin and bushing
Interference between master pin and link
38.25 Standard size 38.25 Standard size
Clearance between master pin and bushing
Tolerance Shaft 0 -0.05 0 -0.04
38.25
Standard size 38.25
Shaft
Hole
0 0.8 -0.04 0.5 Tolerance
Shaft -0.08 -0.11
Hole -0.23 -0.29
Tolerance
Shaft
Hole
-0.5 -0.7
1 0.5
SA 4-22
Hole -0.25 -0.32 –0.23 –0.29
Tolerance
NY
24
Interference between bushing and link
LA
20
Standard size
A
Shoe bolt
Triple grouser 750±22.5 120±10 shoe {62.5±2.3} Retighten Tightening torque Retightening angle Lower limit torque (Nm {kgm}) (°) (Nm {kgm}) — — —
TI N
19
Retightening angle (°)
Standard interference 0.20 – 0.32 0.19 – 0.29
AM E
a. Regular link
Remedy
RI C
No.
Shop Manual - June 2013
Standard clearance 0.50 – 0.84
Standard interference 0.12 – 0.21 Standard clearance 1 – 1.7
Adjust or replace
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.3.6 Triple grouser shoe
1
6
4
AM E
3
RI C
8
1
Height
2
Thickness
3 4
Length of base
5 7
Thickness
2
ZX215 1002014
Unit: mm Remedy
Standard size
Repair limit
26
16 10 29.5 22
Build-up welding or replace
20.5 17 18
Standard size
Repair limit
36
26
SA
8
Length at tip
NY
6
Criteria
TI N
Check item
LA
No.
7
A
5
Shop Manual - June 2013
4-23
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.4 Hydraulic System, Part 1
2)
Arm cylinder
3)
Boom cylinder
4)
Hydraulic tank
5)
Hydraulic oil filter
6)
Control valve
7)
Hydraulic pump
8)
Radiator
9)
Accumulator
RI C
Bucket cylinder
AM E
1)
A
4.4.1 Hydraulic equipment layout
10) Left travel motor 11) Right travel motor 12) Swing motor 13) Lockout lever
1
TI N
14) Left pilot valve 15) Center swivel joint 16) Right pilot valve
LA
17) Travel pilot valve 18) Solenoid valve assembly
18A. Pilot lockout solenoid valve
18B. Boom priority solenoid valve
NY
18C. Bucket confluence solenoid valve 18D. Swing priority solenoid valve
SA
18E. Hi/Lo travel speed solenoid valve
4-24
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
3
5
6
7
8
LA
TI N
AM E
4
RI C
A
2
A
SA
NY
9
10 11 12 13 14 15 17
A 18A
16
18B
18C
18D 18E
18 W13081903
Shop Manual - June 2013
4-25
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.4.2 Hydraulic tank and filter
2
4
5
6
TI N
3
AM E
RI C
A
1
A
SA
NY
LA
A
7
A-A ZX215-1002017
1)
Hydraulic tank
Specifications
2)
Level gauge
3)
Oil filler cap
Tank capacity: 239 L (63 US gal) Available capacity: 172 L (45.5 US gal)
4)
Return oil filter element
5)
Bypass valve
6)
Breather valve
7)
Oil-suction filter element
Breather valve Filter fineness: 10μm Ambient temperature: -20~100°C Set pressure: Air inlet side: 0.005MPa Air outlet side: 0.05MPa
4-26
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.4.3 Hydraulic pump Type: K3V112DTP1N9R PH1
PH2
a2 {36N·m}
A1
A2
RI C
A
a1 {36N·m}
a5 {16N·m}
TI N
AM E
a4 {36N·m}
Clockwise
B3
DR1{170N·m}
Psv2
5
LA
B1
DR2{170N·m} a3 {36N·m}
SA
NY
4
A3 DR3{170N·m} 3
2
DR4{170N·m} 1
ZX215-1002018
Shop Manual - June 2013
4-27
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Outline ● This pump consists of 2 variable capacity swash plate plunger pumps, 2 regulators, and 1 pilot gear pump. NOTE: For the location of the hydraulic pump on the machine, see “Hydraulic equipment layout” on page 4-24. F. pump main pressure detection port
1)
Front pump
a2:
R. pump main pressure detection port
2)
Rear pump
a3:
F. pump regulator pressure detection port
3)
Pilot gear pump
a4:
Adjustor control pressure detection port
4)
Front pump regulator
a5:
Pilot gear pump output pressure detection port
5)
Rear pump regulator
PH1:
F. pump pressure sensor assembly port
PH2:
R. pump pressure sensor assembly port
A1:
F. pump delivery port
A2:
R. pump delivery port
A3:
Pilot gear pump delivery port
Psv2: R. pump regulator control port F. pump drain plug
Dr2:
R. pump drain plug
Dr3:
Air bleeder
Dr4:
Drain plug
B1:
Pump suction port
B3:
Pilot gear pump oil suction port
SA
NY
LA
Dr1:
4-28
RI C
AM E
TI N
Psv1: F. pump regulator control port
Shop Manual - June 2013
A
a1:
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
2
3
13
6
7
14
8
9
16
10
RI C
A
15
5
1)
Front shaft
2)
Min. delivery adjusting screw
3)
Front casing
4)
Swash plate
5)
Slipper
6)
Plunger
7)
Cylinder block
8)
Valve plate
9)
TI N
4
AM E
1
12
11 ZX215-1002019
End cover
10) Rear shaft 11) Rear casing
LA
12) Gear pump 13) Piston 14) Max. delivery adjusting screw 15) Gear shaft
SA
NY
16) Driving pin
Shop Manual - June 2013
4-29
Structure and Function
6
13
7
8
RI C
A
B
SY195/205/215/225C9 Crawler Hydraulic Excavator
18
4
A
5
AM E
1
17
TI N
Function
LA
● The torque of the engine is transmitted to the pump shaft (1), and drives cylinder block (7) to rotate. At the same time, nine plungers (6) slide along the thrust plate (8). Plunger (6) moves back and forth inside cylinder block (7) and pressurized oil is sucked and discharged alternatively.
SA
NY
● It is possible to change the discharge amount by changing the swash plate angle.
4-30
Shop Manual - June 2013
18
ZX215-1002020
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Structure ● Cylinder block (7) is supported to shaft (1) by spline (17). ● Shaft (1) is supported by front and rear bearings (18).
A
● Tip of plunger (6) is shaped as a concave ball and slipper (5) is caulked to it to form one unit.
● Swash plate (4) conducts high pressure oil to cylinder surface (B), and forms a static pressure bearing when it slides.
AM E
● Swash plate (4) has flat surface (A), and slipper (5) is always pressed against this surface while sliding in a circular movement.
RI C
● Plunger (6) and slipper (5) constitute the spherical bearing.
TI N
● Plunger (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7).
LA
● Cylinder block (7) seals the pressurized oil to thrust plate (8) and carries out relative rotation.
NY
● This surface is designed so that the oil pressure balance is maintained at a suitable level.
SA
● The oil inside the respective cylinder chambers of cylinder block (7) is sucked in and discharged through thrust plate (8).
Shop Manual - June 2013
4-31
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Operation of pump ● Cylinder block (7) rotates together with shaft (1), and slipper (5) slides on flat surface (A).
4
7 A
a
A
X B
ZX215-1002021
● (a) is named the swash plate angle.
● With central line (X) of swash plate (4) at a swash plate angle (a) in relation to the axial direction of cylinder block (7), flat surface (A) acts as a cam in relation to slipper (5).
5
AM E
4
6
A
F
a
TI N
● In this way, plunger (6) slides on the inside of cylinder block (7), so a difference between volumes (E) and (F) is created inside cylinder block (7).
5
RI C
● When this happens, swash plate (4) moves along cylindrical surface (B), so angle (a) between central line (X) of swash plate (4) and the axial direction of cylinder block (7) changes.
1
X
E
7
ZX215-1002022
LA
● A single plunger sucks and discharges the oil by the amount (F) – (E).
NY
● As cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the pressurized oil is discharged.
SA
● On the other hand, the volume of chamber (F) grows larger and, in this process, the oil is sucked. ● As central line (X) of swash plate (4) overlaps the axial direction of cylinder block (7) (swash plate angle (a) = 0), the difference between volumes (E) and (F) inside cylinder block (7)becomes 0. ● Suction and discharging of pressurized oil is not carried out in this state. Namely pumping action is not performed. (In reality, however, the swash plate angle is not set to 0)
4-32
Shop Manual - June 2013
F
E 4
7 ZX215-1002023
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Control of delivery ● If swash plate angle (a) becomes larger, the difference between volumes (E) and (F) becomes larger and pump delivery (Q) increases.
13 16
F
● Piston (13) carries out linear alternating motion under the control of the adjustor.
RI C
a
E
ZX215-1002024
AM E
4
SA
NY
LA
TI N
● This linear motion is transmitted to swash plate (4) via drive pin (16). The sliding of the swash plate changes the swash plate angle and changes the discharge amount of the main pump.
A
● Piston (13) is used for changing swash plate angle (a).
Shop Manual - June 2013
4-33
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.4.4 Pilot pump NOTE: For the location of the pilot pump on the machine, see “Hydraulic equipment layout” on page 4-24.
433
710
354
700
351
RI C
A
435
434 310
AM E
355
732
311
307
307: Valve stem 308: Valve base
434
850
466
725
361: Body 433: Screw 434: Screw 435: screw
NY
309: Retainer 310: Spring
308
LA
309
TI N
312
466: Plug
312: Nut
700: Washer
SA
311: Adjusting screw 351: Body
710: O-ring
353: Gear shaft
725: O-ring
354: Gear shaft
732: O-ring
355: Filter element
850: Washer
Function ● The engine actuates the main pump and the drive shaft of the pilot pump through the transmission case, and drives the pilot pump through gear engagement.
4-34
Shop Manual - June 2013
435
361
353 ZX215-1002025
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.4.5 Regulator (KR3G-0E11-AV) NOTE: Both the front pump and the rear pump are equipped with a regulator. For the location of the hydraulic pump, see “Hydraulic equipment layout” on page 4-24.
A
079
418
PSV
B 624
627
646
897
415
AM E
KDRDE5C-1
A
325
a
408
RI C
SKY5P - 17 - S
496
496
924 801
755 466
402 656
643
407
A
733
631
TI N
(KDRDE5K)
651 652 733
PSV
Part No.
a
887
543
755
756
708
545
611
541
A-A
Tightening torTue
LA
731
724
601
614
402, 407 408 415
Name plate and s/n Tightening torTue
Nm
M6
12
M8
29
M5
6.9
466
G1/4
16
496
NPTF1/16
8.8
614
G1/4
36
801
M10
29
418
NY
Thread size
Type s/n G-OE11-V
Direction B
SA
Hydraulic schematic diagram
ZX225-1102002
Shop Manual - June 2013
4-35
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Category
Part No.
Part name
Q’ty
C
924
Hexagon socket head locating screw
1
/
897
Pin
1
/
887
Pin
1
D
801
Hexagon nut
1
D
756
O-ring
2
D
755
O-ring
2
D
733
O-ring
2
D
731
O-ring
1
D
724
O-ring
5
D
708
O-ring
1
/
656
Cover plate
1
/
652
Spool valve
1
/
651
Sleeve
/
646
Guide spring
/
643
Pilot plunger
/
631
Pf pilot sleeve
/
627
Adjusting roller
1
/
624
Spring seat
1
/
614
Plug
/
611
Feedback lever
1
/
601
Casing
1
/
545
Ball
2
/
543
Stopper
2
/
541
Valve seat
2
C
496
Embedded plug
9
466
VIP plug
1
418
Hex socket head bolt
2
JIS B 1176 M5-12
415
Hex socket head bolt
6
JIS B 1176 M8-50
408
Hex socket head bolt
1
JIS B 1176 M6-40
407
Hex socket head bolt
4
JIS B 1176 M6-30
D
402
Hex socket head bolt
4
JIS B 1176 M6-16
/
325
Valve body
1
B
079
Sol proportional reducing valve
1
B
—
Regulator assembly
1
D D D
B: /: C: D: 4-36
AM E
RI C
A
JIS B 1181 N-M10
LA
TI N
1
NY
D
SA
C
Remark
1
1
1
1
Assembly obtainable at the dealers (individual parts not purchasable) Individual components included in assemblies of category B Parts obtainable at the dealers Parts obtainable on the market Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Function ● The regulator controls the pump discharge amount according to the command signal pressure, keeping the driving power of the pump lower than the engine output. a
2
3
RI C
A
1
AM E
● Pumps 1 and 2 are both equipped with a regulator. Key components of the regulator include a solenoid proportional pressure reducing valve (1), a positive flow regulator (2), a servo reversing valve (3) and a servo piston (4). The regulator opens and shuts the oil circuit of the servo piston (3) and changes the tilting angle of the hydraulic tank according to various command signal pressure so as to control the pump discharge amount.
PSV
4 ZX225-1102003
TI N
4.4.5.1 Control mechanism makeup Current control
SA
NY
LA
● The inclination (output delivery amount) of the pump can be controlled freely by changing of the command current I flowing into the solenoid proportional pressure reducing valve. This regulator applies positive flow control (positive control), through which output delivery amount Q changes according to the increase of command current. Necessary current for corresponding operation can be input through this control mechanism. The pump only delivers necessary oil amount and wastes no useless power.
Shop Manual - June 2013
4-37
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.4.5.2 Adjustment of the regulator
806
532
548 531
808
954
531: Inclination pin 532: Servo piston
PSV
806: Retaining nut 808: Retaining nut
LA
548: Feedback pin
ZX215-1002028
SKY5P - 17 - S
KDRDE5C-1
TI N
AM E
RI C
A
953
924
NY
953: Adjusting screw 954: Adjusting screw
SA
● It is possible to adjust the maximum and minimum flow by the adjusting screws (953, 954) in the pump block side. Flow control features can be adjusted with the hexagon socket head locating screw (924) on the regulator.
4-38
Shop Manual - June 2013
ZX225-1102004
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Maximum flow adjustment (pump block side)
RI C
A
Output flow Q
● Loosen the hexagon nut (808), and tighten (or loosen) hexagon socket head locating screw (954). No control features except the maximum flow changes.
NY
LA
● Loosen the hexagon nut (806), and tighten (or loosen) the hexagon socket head locating screw (953). Though this action is the same as the adjustment of maximum flow and all the other control features do not change, power required under maximum output pressure (overflow) is likely to increase if over-tightened. Be careful in this case.
ZX215-1002033
Output flow Q
TI N
Minimum flow adjustment (pump block side)
AM E
Command current I
SA
Command current I ZX215-1002034
Shop Manual - June 2013
4-39
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
RI C
A
● After hexagon nut (810) is loosened, tighten (or loosen) the hexagon socket head locating screw (924) to carry out adjustment. When the hexagon socket head locating screw (924) is being tightened, the control diagram (as shown) will move to the right.
Output flow Q
Flow control feature adjustment
Command current I
AM E
ZX215-1002037
Flow control
NY
LA
● The output flow of the pump can be controlled by the command current I, as shown.
Output flow Q
TI N
4.4.5.3 Operation
Command current I
SA
ZX215-1002030
4-40
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Action of increasing flow rate
627 646
643
801 924
P1
611 532
A
808
806 953
A
954 P1
Tilt angle large
TI N
● Since feedback lever (611) is integrated with the servo piston and valve sleeve (651), if servo piston (632) moves to the left, feedback lever swings with point A as the pivot. In this way, valve sleeve moves to the right.
651 652
RI C
● As spool valve (652) moves to the right, because port cl and tank port are interconnected, pressure of the large diameter portion of the servo piston is released and servo piston (532) moves to the left via the output pressure P1 in the shall diameter portion. The inclination becomes larger.
079
AM E
● When command current I increases, the solenoid proportional pressure reducing valve secondary pressure P2 will increase, and the spool valve (652) will move the right with the help of the guide piston (643). When a relative balance between the rightward hydraulic force and the spring force of guide spring (646) is achieved, spool valve (652) stops moving.
ZX225-1102005
PSV
a
NY
LA
● Through this movement, the opening portion between the spool and the valve block is closed slowly. The servo piston stops moving when the opening portion is completely closed.
SA
ZX225-1102006
Shop Manual - June 2013
4-41
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Action of reducing flow rate
651 652 627 646
643
801 924
P1
611 532
A
808
806 953
A
954
RI C
P1
Tilt angle small
ZX225-1102007
PSV
a
NY
LA
TI N
● As servo piston (532) moves to the right, the feedback lever swings with point A as the pivot and the valve sleeve moves to the left. Through this movement, the opening portion between the spool and the valve block is slowly closed. The servo piston stops moving when the opening portion is completely closed.
079
AM E
● When command current I decreases, the solenoid proportional pressure reducing valve secondary pressure P2 will decrease, and guide piston (643) will move to the left. However, as spool valve (652) moves, output pressure P1 is introduced into the large diameter chamber of the servo piston via the port cl. On the other hand, output pressure P1 is introduced into the small diameter chamber of the servo piston and servo piston moves to the right via are difference. The inclination becomes smaller.
ZX225-1102008
SA
Adjustment value of the regulator Type of regulator
KR3G-0E11-AV
-1
Rotating speed (min )
Adjustment of max. flow Adjustment of min. flow
4-42
2050 Adjusting screw (954) screw-in (rotation)
+1/4
Flow rate change (L/min)
-5.9
Adjusting screw (953) screw-in (rotation)
+1/4
Flow rate change (L/min)
+4.7
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.5 Hydraulic System, Part 2 4.5.1 Control valve NOTE: For the location of the control valve on the machine, see “Hydraulic equipment layout” on page 4-24. XBp2
XAa1
BaR
A
(XAo)
RI C
XAa2
BoR BkR
Psp
BbR
XBtr
XAs
AM E
XAb1
Dr2
XBtL
(PTa)
XBtr Dr3
PnA2
TI N
Dr6
Dr7
Pz
PX
AtL
PbL
LA
Pns
TRAVEL LEFT
BUCKET
XAk ARM2
SA
XBa2
Aa(Rod)
Ak(Head)
Atr
TRAVEL RIGHT
SWING
Dr1
Bb(Rod)
XBs BOOM2
SWING PRIORITY
AbR OPTION
PCk XBk Bk(Rod)
AkR
(Bo)
Dr3
(BYPASS CUT 1)
DR3
XAb2 (XBo)
ARM1
AoR PCV1
AaR
R2
PaL
As
XAtr
BtL
NY
XBb1
BOOM1
Btr
MR
Py
TRAVEL STRAIGHT
XAtL
Bs
PG
XBa1 (XBp1)
Ba(Head)
Ab(Head)
(Ao) P1
P2
R1
R1
ZX225-1102009
Shop Manual - June 2013
4-43
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
XBp2: Bypass cut spool pilot port (P2 side)
XBtr : R. travel (forward) pilot port
XAb2: Boom confluence (UP) pilot pressure
(XAo): (Option pilot port)
Psp:
Swing priority pilot port
(XBo): (Option pilot port)
R1:
Return port
XAk:
Bucket (DIG) pilot port
R2:
Oil feed port
XBk:
Bucket (DUMP) pilot port
Atr:
R. travel motor port (reverse)
XAb1: Boom 1 (UP) pilot port
Btr:
R. travel motor port (forward)
XBb1: Boom 2 (DOWN) pilot port
(Ao):
Option
XAa2: Arm 2 (OUT) pilot port
(Bo):
Option
XBa2: Arm 2 (IN) pilot port
Ak:
Bucket cylinder head end port (DIG)
XAtL: L. travel (reverse) pilot port
Bk:
Bucket cylinder rod end port (DUMP)
XBtL: L. travel (forward) pilot port
Ab:
Boom cylinder head end port (UP)
XAs:
Swing (left) pilot port
Bb:
Boom cylinder rod end port (DOWN)
XBs:
Swing (right) pilot port
AtL:
XAa1: Arm 1 (OUT) pilot port
BtL:
XBa:
Arm 1 (IN) pilot port
As:
Dr1:
Drain port
Bs:
Px:
Work equipment signal port
Aa:
Py:
Travel signal port
Pz:
L. travel motor port (reverse) L. travel motor port (forward) Swing motor port (left swing) Swing motor port (right swing)
Arm cylinder rod end port (OUT) Arm cylinder head end port (IN)
Main relief valve boosting pressure
P1:
Pump port (P1 side)
PG:
Pilot pressure resource port
P2:
Pump port (P2 side)
Pns:
Swing logic control valve pilot port
MR:
Main relief valve
PCK: Bucket (DIG) stroke limit pilot port
AR:
Arm regeneration check valve
PnA2: Arm 2 logic control valve pilot port
AbR:
Port relief valve
Dr2:
Drain port
BbR:
Port relief valve
Dr3:
Drain port
AkR:
Port relief valve
Dr6:
Drain port
BkR:
Port relief valve
Dr7:
Drain port
AoR:
Port relief valve
Pal:
Lock valve pilot port (arm rod end)
BoR:
Port relief valve
Lock valve pilot port (boom head end)
AaR:
Port relief valve
BaR:
Port relief valve
PbL:
NY
LA
Ba:
SA
TI N
AM E
RI C
A
XAtr : R. travel (reverse) pilot port
(XBp1):Bypass cut spool pilot port (P1 side)
NOTE: For more technical information about the control valve, see “Control valve” on page 3-6.
4-44
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Hydraulic circuit diagram (with bucket confluence function)
(P3)
P2
R1
(P0)
P1
PG
d1 ĭ0.7
d3 ĭ0.7
d2 ĭ0.7
CMR2
MR
CMR1 XBtr
TRAVEL R
Pz
(PTa)
TRAVEL STRAIGHT
XAtr Atr Btr
XBs
RI C
LCs 4-ĭ2.1
XAs As Bs Pns
C2
AM E
SWING PRIORITY
A
CP1
Dr2 Dr6
SWING
Px
CPG
Psp
Py
TRAVEL L
XBtl XAtl Btl Atl Dr1
LCb
BOOM2XAb2
XBb1
BOOM1
XAb1 AbR
Bb (ROD)
BbR
TI N
CCb
Ab (HEAD) HVb PbL
LCk
LCo
(XBo) (XAo)
AoR
(Ao) (Bo)
AR Dr3
LA
OPTION
PCk XBk
(ROD) Bk Ak (HEAD)
BkR
AkR
BoR
LCa
2-ĭ1.0 2-ĭ2.0
LCAP2
PnA2 Dr7
LCAT2
XAa1
XBa2
NY
ARM1
BUCKET
XAk
ARM2
XAa2
XBa1 (HEAD) Ba
AaR
SA
BaR
BYPASS CUT
Aa (ROD)
CCo HVa CCk
PaL
(XBp1) R2
XBp2 (P5)
ZX225-1102010
Shop Manual - June 2013
4-45
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.5.2 Operating principle 4.5.2.1 When spool is in neutral position [Main circuit]
AM E
RI C
A
● Working oil supplied from the hydraulic pump (Rear) flows in through pump port P2 and is introduced into the main passage (3). It passes the neutral bypass (2) (neutral M-shaped spool mechanism) of the spools of R travel (301), swing (305), boom confluence (boom 2: 307), option (309), arm 1 (302), and flows back into the working oil tank via return port (R1).
SA
NY
LA
TI N
● When all the spools are in neutral position, working oil supplied from the hydraulic pump (Front) flows in through pump port P1 and is introduced into the main passage (1). It passes the neutral bypass (2) (neutral M-shaped spool mechanism) of the spools of straight travel (308), L. travel (301), boom 1 (303), bucket (304) and arm 2 (306), and flows back into the working oil tank via return port (R1).
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Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
(2)
(1)
XAtL
XBtL
XBb1
XAbL
PCk
RI C
XAk
A
(PTa)
X8k XAa2
AM E
XBa2
CCo CCk P2
XBtr
Psp
R1
LA
XAs
(P3)
TI N
(3)
(XAo)
XAa1
(2)
XAtr
XBs
XAb2
(XBo)
NY
XBa1 (XBp1)
SA
XBp2
ZX225-1102011
Shop Manual - June 2013
4-47
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.5.2.2 Travel
● When pressure at pilot port XBtL for left travel spool (301) rises, neutral bypass (2) at boom 1 side is closed, and working oil supplied from the hydraulic pump (front) is introduced into the left travel motor via port Btl.
● On the other hand, return oil from the left and right travel motor passes the left (right) travel spool via port Atl (Atr), and returns to working oil tank via return port (R1).
A
[Main circuit]
RI C
● When the left or right travel spool is switched, the side bypass circuit is closed and pressure at port Py (travel signal port) rises.
● Likewise, when pressure at port XBtr for the right travel spool (301) rises, neutral bypass (2) at arm 1 side is closed, and working oil supplied from the hydraulic pump (rear) is introduced into the right travel motor via port Btr.
● The principle is the same when travel on the opposite side is operated (when pressure at pilot port XAtr and XAtl rises).
AM E
[Pilot circuit]
XBtr
Atr
Btr
SA
NY
LA
TI N
XAtr
Travel motor ZX225-1102012
4-48
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.5.2.3 Arm (1) Arm OUT [Pilot circuit]
● Return oil from the arm cylinder head end (H) via port Ba flows into the tank circuit of arm 1 and arm 2, and returns to working oil tank via tank port (R1).
SA
NY
LA
TI N
● When arm OUT is operated, pilot pressure oil is supplied into port XAa1 and port XAa2. When pilot pressure oil is applied at the two sides of port XAa1 and port XAa2, arm 1 spool and arm 2 spool are switched to the left as shown in the illustration. As a result, working oil from P2 is introduced into neutral bypass (2) via main passage (3). Neutral bypass is cut off by switching arm 1 spool (302). Therefore, working oil in the parallel passage pushes open the cone valve (511) of the check valve, and flows into the arm 1 spool (302) via the U passage. Then, it flows into the periphery of arm 1 spool (302) and arm 2 spool (306) and is supplied into the arm cylinder rod end (R) via port As.
AM E
[Main circuit]
RI C
A
● When the arm 2 spool (306) is switched, the side path is closed and pressure at port Px (work equipment signal port) rises.
● On the other hand, working oil from port P1 is introduced into neutral bypass (2) via main passage (1). Neutral bypass is cut off by switching the arm 2 spool (306). Therefore, working oil in the parallel passage pushes open the logic cone valve (256-101) of the arm 2 logic valve GP, and working oil from neutral bypass pushes open the cone valve (511) of the check valve and flows into the arm 2 spool (306) via the U passage. Then, it merges with port As via the inner passage of arm 2 spool (306) and is supplied into the arm cylinder rod end (R).
Shop Manual - June 2013
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
R
256-101
511
TI N
AM E
Aa
RI C
A
H
XAa2
SA
NY
LA
XAa1
Ba 511 ZX225-1102013
4-50
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
(2) Arm IN from neutral bypass pushes open the cone valve (511) of the check valve and flows into the arm 2 spool (306) via the U passage. Then, it merges with port Ba via the inner passage of arm 2 spool (306) and is supplied into the arm cylinder head end (H).
[Pilot circuit]
A
● If the pressure at the arm cylinder head end and in the U passage rises, arm regeneration check valve spool (257-211) switches to the left. And, at the same time, the back pressure of the cone valve (302317) in the spool is closed. Therefore, arm regeneration function is released and return oil from the arm cylinder rod end (R) flows into the spool via the hole (a) on the periphery of arm 1 spool (302). Then, it flows into arm regeneration check valve set (257) via hole (c) on the periphery of arm 1 spool (302), and returns to the working oil tank via tank port R1.
LA
TI N
● When arm In is operated, pilot pressure oil is supplied to port XBa1 and port XBa2. When pilot pressure oil is applied at the two sides of port XBa1 and port XBa2, arm 1 spool and arm 2 spool is switched to the left. As a result, working oil from P2 is introduced into the neutral bypass (2) via main passage (3). Neutral bypass is cut off by switching arm 1 spool (302). Therefore, working oil flown into the parallel passage pushes open the cone valve (511) of the check valve and flows into the arm 1 spool (302) via the U passage. Then, it flows into the periphery of arm 1 spool (302) and is supplied into the arm cylinder head end (H) via port Ba.
RI C
[Main circuit]
● On the other hand, pressure of the return oil from the arm cylinder rod end (R) rises under the weight the arm, and the return oil returns to port Aa. Working oil that returns to port Aa flows into the inside of the valve spool via the holes on the periphery of the arm 1 spool (302), and pushes open the cone valve (302-317) in the spool only under light load. It merges with port Ba through the holes on the spool. This is called the regeneration function of the arm.
AM E
● When the arm 2 spool (306) is switched, the side path is closed and pressure at port Px (work equipment signal port) rises. At the same time, pressure oil is supplied to port PaL and the release signal of lock valve option set (252) is sent out.
SA
NY
● On the one hand, working oil from port P1 is introduced into neutral bypass (2) via main passage (1). Neutral bypass is cut off by switching the arm 2 spool (306). Therefore, working oil in the parallel passage pushes open the logic cone valve (256-101) of the arm 2 logic valve GP, and working oil
Shop Manual - June 2013
4-51
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
● Light load
Arm weight R
RI C
A
H
AM E
Aa
TI N
XBa2
LA
(302-317)
SA
NY
XBa1
(b) (a)
Ba ZX225-1102014
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Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
● When pressure at arm cylinder head end (H) rises
R
RI C
A
H
AM E
Aa
TI N
XBa2
LA
(302-317)
NY
XBa1
SA
(c)
(257-211)
(a)
Ba ZX225-1102015
Shop Manual - June 2013
4-53
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.5.2.4 Boom (1) Boom UP
● On the other hand, return oil from the boom cylinder rod end (H) via port Bb flows into the periphery of boom 1 spool (303) and returns to the working oil tank via tank port (R1).
SA
NY
LA
TI N
● When boom UP is operated, pilot pressure oil is supplied into port XAb1 and boom 1 spool (303) moves to the left. Working oil from port P1 is introduced into neutral bypass (2) via main passage (1). Neutral bypass is cut off by switching boom 1 spool (303). Therefore, working oil in the parallel passage pushes open the cone valve (511) of the check valve, and flows into the boom 1 spool (303) via the U passage. Then, it flows into the periphery of boom 1 spool (303) and is supplied into the boom cylinder head end (H) via port Ab.
A
[Main circuit]
RI C
● When the boom 1 spool (303) is switched, the side path is closed and pressure at port Px (work equipment signal port) rises.
● At the same time, pilot pressure oil is also supplied to port XAb2 and boom 2 spool (307) moves to the right. Working oil from port P2 is introduced into neutral bypass. Neutral bypass is cut off by switching the boom 2 spool (307). Therefore, working oil in the parallel passage flows into boom 2 spool (307) via the U passage. Then, it pushes open the cone valve (511) of the check valve and merges with port Ab and is supplied into the boom cylinder head end (H). This is called the boom confluence function.
AM E
[Pilot circuit]
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Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
H
R
Ab
AM E
RI C
Bb
A
511
511
ZX225-1102016
SA
NY
LA
TI N
XAb2
XAb1
Shop Manual - June 2013
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
(2) Boom DOWN passage. Then, it flows into the periphery of boom 1 spool (303) and is supplied into the boom cylinder rod end (R) via port Bb.
[Pilot circuit]
● On the other hand, return oil from the boom cylinder head end (H) passes the hole (a) and the periphery of boom 1 spool (303).
A
● When the boom 1 spool (303) is switched, the side path is closed and pressure at port Px (work equipment signal port) rises. At the same time, pressure oil is supplied to port PbL and the release signal of lock valve option set (252) is sent out.
RI C
LA
TI N
● When boom DOWN is operated, pilot pressure oil is supplied to port XBb1. Boom 1 spool (303) moves to the right. As a result, working oil from P1 is introduced into the neutral bypass (2) via main passage (1). Neutral bypass is cut off by switching boom 1 spool (303). Therefore, working oil flown into the parallel passage pushes open the cone valve (511) of the check valve and flows into the boom 1 spool (303) via the U
● Return oil pressure rises due to the self weight of the boom. Cone valve (303-317) in the spool is pushed to the right. Return oil flows to the outside of spool. The pressure oil is supplied into the boom cylinder rod end (R) as the working oil for boom DOWN operation. This is called the boom regeneration function. Part of the oil that flows into the inside passage of the spool via hole (a) returns to the working oil tank via hole (b).
AM E
[Main circuit]
H
R
Ab
Bb
SA
NY
511
XBb1
(b)
(a)
(303-317) ZX225-1102017
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Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.5.2.5 Bucket (1) Bucket DIG Then, it flows into the periphery of bucket spool (304) and is supplied into the bucket cylinder head end (H) via port Ak.
[Pilot circuit]
A
● When boom UP and bucket DIG are operated simultaneously, pilot pressure oil is supplied to port Pck. Therefore, the stroke of bucket spool is not limited at stroke end, but on any position halfway. As a result, bucket cylinder passage is throttled and working oil flows into boom 1 spool (303) via bucket spool (304). In this way, boom UP operation takes precedence.
TI N
● When bucket DIG is operated, pilot pressure oil is supplied into port XAk and bucket spool (304) moves to the right. Working oil from port P1 is introduced into neutral bypass (2) via main passage (1). Neutral bypass is cut off by switching bucket spool (304). Therefore, working oil in the parallel passage pushes open the cone valve (511) of the check valve, and flows into the bucket spool (304) via the U passage.
RI C
[Main circuit]
● On the other hand, return oil from the bucket cylinder rod end (R) flows in via port Bk. Then, it flows to oil tank port (R1) via the spool periphery and returns to working oil tank.
AM E
● When the bucket spool (304) is switched, the side path is closed and pressure at port Px (work equipment signal port) rises. At the same time, pressure oil is supplied at port XBp2.
R
Ak
Bk
SA
NY
LA
H
XAk
H
Pck
ZX225-1102018
Shop Manual - June 2013
4-57
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
(2) Bucket DUMP
[Main circuit]
● On the other hand, return oil from the bucket cylinder head end (H) flows in via port Ak. Then, it flows to oil tank port (R1) via the spool periphery and returns to working oil tank.
AM E
● When bucket DUMP is operated, pilot pressure oil is supplied into port XBk and bucket spool (304) moves to the left. Working oil from port P1 is introduced into neutral bypass (2) via main passage (1). Neu-
A
● When the bucket spool (304) is switched, the side path is closed and pressure at port Px (work equipment signal port) rises. At the same time, pressure oil is supplied at port XBp2.
tral bypass is cut off by switching bucket spool (304). Therefore, working oil in the parallel passage pushes open the cone valve (511) of the check valve, and flows into the bucket spool (304) via the U passage. Then, it flows into the periphery of bucket spool (304) and is supplied into the bucket cylinder rod end (R) via port Bk.
RI C
[Pilot circuit]
R
LA
Ak
TI N
H
Bk
SA
NY
XBk
ZX225-1102019
(3) Bucket confluence ● When bucket DIG is operated, pilot pressure oil is supplied into port XBp2 and the neutral bypass cutoff valve spool (310) is switched. Working oil from port P2 is introduced into neutral bypass (2) via main passage (3). Neutral bypass is cut off by
4-58
switching neutral bypass valve spool (310). Therefore, working oil pushes open the check valve, and interconnects with the U passage via the inside path, and converges with bucket spool (304).
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.5.2.6 Swing (1) Swing operation (305). Therefore, working oil in the parallel passage pushes open the logic cone valve (2540-101) of the swing logic valve GP, and flows into the swing spool (305) via the U passage. Then, it flows into the periphery of swing spool (305) and is supplied into the swing motor via port As (or Bs).
[Pilot circuit] ● When the swing spool (305) is switched, the side path is closed and pressure at port Px (work equipment signal port) rises.
RI C
XAs
LA
TI N
XBs
● On the other hand, return oil from the swing motor flows in via port Bs (or port As). Then, it flows into tank port (R1) via the spool periphery and returns to the working oil tank.
AM E
● When swing is operated, pilot pressure oil is supplied into port XAs (or XBs) and swing spool (305) is switched. Working oil from port P2 is introduced into neutral bypass (2) via main passage (3). Neutral bypass is cut off by switching swing spool
A
[Main circuit]
Bs
SA
NY
As
(254-101)
Swing motor ZX225-1102020
Shop Manual - June 2013
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
(2) Swing priority function [Pilot circuit] ● Pilot pressure oil is supplied to port Psp and swing priority spool (311) is switch.
Psp
SA
NY
LA
TI N
AM E
RI C
A
[Main circuit]
● Switch swing priority spool (311). The opening area of the swing priority reduces. As a result, working oil from arm 1 spool (302) flows into swing spool (305) and swing operation takes precedence.
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Shop Manual - June 2013
ZX225-1102021
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.5.2.7 Option Option spool is used to control optional work equipment attachment. (1) Operation (309). Therefore, working oil in the parallel passage pushes open the cone valve (511) of the check valve, and flows into the option spool (309) via the U passage. Then, it flows into the periphery of option spool (309) and is supplied into the optional equipment via port Ao (or Bo).
[Pilot circuit]
A
● When the option spool (309) is switched, the side path is closed and pressure at port Px (work equipment signal port) rises.
● On the other hand, return oil from the optional equipment flows in via port Bo (or port Ao). Then, it flows into tank port (R1) via the spool periphery and returns to the working oil tank.
AM E
● When option is operated, pilot pressure oil is supplied into port XAo (or XBo) and option spool (309) is switched. Working oil from port P2 is introduced into neutral bypass (2) via main passage (3). Neutral bypass is cut off by switching option spool
RI C
[Main circuit]
XAo
Ao
Bo
SA
NY
LA
TI N
XBo
ZX225-1102022
(2) Option confluence ● To achieve option confluence, pilot pressure oil is supplied into port XBp1 and the bypass cutoff valve spool (310) is switched. Working oil from port P1 is introduced into neutral bypass (2) via main passage (1).
Neutral bypass is cut off by switching bypass valve spool (310). Therefore, working oil pushes open the cone valve (514) of check valve, and converges with option spool (309) via the inside path and the U passage.
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.5.2.8 Travel straight
● The side path of right/left travel spool (301) and the side path of the swing spool (305) at the downflow side are closed.
● On the other hand, working oil from port P1 is supplied to the swing motor via port As. ● When oil pressure at port P2 is lower than that at port P1, part of the working oil form port P1 is supplied to port P2. In this way, sharp decrease of travel speed is averted.
P1
P2
PTa
SA
NY
LA
TI N
● Pilot oil from port PG is supplied to port PTa and straight travel spool (308) is switched.
A
[Pilot circuit]
● When straight travel spool (308) is switched, the right/left travel spool (301) are interconnected with port P2. The parallel passage of swing/boom 2/option/arm 1 circuit and boom 1/bucket/arm 2 circuit are interconnected with port P1. Therefore, working oil supplied from port P2 flows into port Atl and port Atr, and is supplied to the two travel motors equally.
RI C
The following case shows when travel spool (301) and swing spool (305) are operated simultaneously. (When pilot pressure oil is supplied to port XAtL, port XAtr and port Xas)
[Main circuit]
AM E
When travel spool (301) and other spool are operated simultaneously.
ZX225-1102023
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Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.5.2.9 Lock valve function
(1) Spool in neutral position ● The following shows when boom 1 spool (303) is in neutral position. (The same is with arm 2 spool (306))
A
252-511 252-541
LA
(b)
TI N
252-321
● At this position, working oil at the boom cylinder head end (H) flows in via hole (a) and flows out from hole (b) through the periphery of the lock valve option set spool (252-511), pressing the cone valve (513) against the valve seat of the valve block via hole (b). By this means, oil leakage is reduced.
RI C
● Likewise, lockout option set (252) is also installed between boom cylinder head end (H) and boom 2 spool (303) to reduce the internal leakage of he spool due to cylinder pressure.
● When boom 1 spool (303) is in neutral position, spool (252-511) in the lock valve option set is pressed against the valve seat of the valve sleeve (252-541) inside the lock valve option set, as shown in the illustration, via the spring force of spring (252321).
AM E
● The lock valve option set (252) is installed between the arm cylinder rod end (R) and arm 2 spool (302) and arm 2 spool (306). It is used to reduce the internal leakage of the spool due to cylinder pressure.
513
SA
NY
(a)
ZX225-1102024
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4-63
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
(2) Boom DOWN operation
A
into spring chamber (RH). In addition, oil in the spring chamber (RH) flows into drain circuit via hole (b). In this way, the cone valve (513) is pushed up by the pressure at boom cylinder head end (H) and the function of the lock valve option set (252) is released.
252-511
(RH)
AM E
(b)
RI C
● When boom DOWN is operated, pilot pressure oil is supplied to port PbL and port XBb1. Spool (252-511) inside the lock valve option set moves to the top by via pilot pressure oil. Through the movement of spool (252-511) inside the lock valve option set, hole (a) is cutoff and working oil from boom cylinder head end (H) does not flow
513
(a)
LA
TI N
PbL
NY
XBb
SA
ZX225-1102025
(2) Boom UP operation ● When boom DOWN is operated, pilot pressure oil is supplied to port XAb1. The cone valve (513) is pushed ope by the oil from
4-64
boom 1 spool (303) and working oil flows into port Ab.
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.5.2.10 Main relief valve function
611
621
P
R
LA
TI N
541
● When pressure oil high than 3MPa is supplied to port Pz, this pressure oil pushes plunger (614) to the left. The set load of spring (621) is changed and pressure of the main relief valve rises.
AM E
● When pressure in passage (P) exceeds the elastic force of spring (621), cone valve (611) is pushed open. Therefore, working oil flows through the hole on valve sleeve (103) via the periphery of cone valve (611)
● Opening of cone valve (611) causes pressure in chamber (a) to drop and valve rod (512) is open. In this way, working oil in passage (P) flows into low-pressure path (R) directly.
A
● Working oil flows into chamber (a) from passage (P) via the hole of valve seat (541) and hole on valve rod (512). Valve rod (512) is pressed against valve seat (541), forming a tight seal.
and enters low-pressure path (R).
RI C
The main relief valve is installed on the valve block A (101). Its function is described below:
NY
Pz (a)
103
614
ZX225-1102026
SA
512
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.5.2.11 Port relief valve function The port relief valve is installed between the tank port and low-pressure path. In addition to the function as relief valve, it has also the function of anti-cavitation oil complement check valve. Its function is described below: (1) Relief valve function
AM E
RI C
A
● Working oil flows into chamber (B) via the hole (A) on plunger (301). Valve rod (511) is pressed against valve seat (541), and valve seat (541) is pressed onto the valve seat of the valve block, forming a tight seal.
B
TI N
A
P
511
NY
301
LA
R
ZX225-1102027
B
SA
A
541
P
301
R 511
4-66
541
Shop Manual - June 2013
ZX225-1102028
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
● When pressure in passage (P) exceeds the elastic force of spring (621), cone valve (611) is pushed open. Therefore, working oil flows through hole (C) via the periphery of cone valve (611) and enters low-pressure path (R).
RI C
A
C
AM E
P
R
621
ZX225-1102029
TI N
611
LA
C
SA
NY
P
R 611
621 ZX225-1102030
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
● Opening of cone valve (611) causes pressure in chamber (B) to drop and valve rod (511) is open. In this way, working oil in passage (P) flows into low-pressure path (R) directly.
RI C
A
B
R
P
ZX225-1102031
LA
B
611
TI N
511
AM E
P
511
611 ZX225-1102032
SA
NY
R
4-68
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
(2) Anti-cavitation oil complement check valve
AM E
RI C
A
● When negative pressure is formed in path (P), working oil is supplied from path (R). When pressure in path (R) gets higher than pressure in path (P), valve seat (541) moves to the right direction. Therefore, working oil is supplied from path (R) to path (P) via the periphery of valve seat (541) in order to prevent cavitation.
P
TI N
R 541
NY
LA
ZX225-1102033
SA
P
R 541 ZX225-1102034
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.5.3 Section view
B
273×10
A
153 (Po)
561
XAtr
HR
273×12
D
252 PnS 977 978×2
Dr8 E
TRAVEL L
XAtl
SWING
BOOM2
XAb2
E
XAk
XBo
OPTION
BUCKET
F
AM E
G
D BOOM1
XBbl
AbR
F
A
XBs
TRAVEL STRAIGHTC
RI C
C
TRAVEL R
AoR
AkR
XBa1
ARM1
XBa2
AR
(BYPASS CUT1) H BYPASS CUT2
(XBp1)
G
PnA2 Dr7
O
AaR
O 252
AaR
TI N
H
PCV1
ARM2
602
A
B
XBa2
(XBp1)
LA
Dr3
NY
View O-O
SA
274×4
Dr6
CCo
Pns
CCk
(P5)
PnA2
P
Dr7
P
210 561
153 (P5)
Viw P-P
XAa2 273×12 XBp2
XBk 273×10 PCk ZX225-1102035
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Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Section A-A, N-N N 101 159
541
542
543 166
A
550
RI C
(PTa)
N
AM E
XAtL
XBb1
XAbL
PCk
TI N
XAk
XBk XAa2
CCo
CCk
514 521 561 551
551 561 521
514
View A-A
SA
NY
LA
XBa2
XBtL
151 168 151 168
151
PB
168
156
2-156 View N-N
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ZX225-1102036
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Section B-B
153
P2
(P3)
561
R1
975
102
A
975
XBtr
RI C
XAtr
AM E
XAs
Psp
975
XBs 975 XAb2
(XAo)
TI N
(XBo)
975 XAb1
975 XBa1
LA
975
NY
XBp2
SA
975
4-72
975
165
(XBp1)
975 165 View B-B
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165 ZX225-1102037
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Section C-C (Travel right, travel straight)
154 164 TRAVEL RIGHT
201 336
TRAVEL STRAIGHT
201 336 332
XAtr
332
323
321
335
A
335
RI C
320
332
AM E
163 314 165
CP1
165 163
CMR2
NY
Btr
562 562
553 522 512 159
264 204
512
CMR1
SA
163
Pz
553
LA
561
163
308 601
522
511 521 551
261
Atr
TI N
163
332
MR
261
332
159 264 XBtr
(PTa) View C-C
204 164 154 ZX225-1102038
Shop Manual - June 2013
4-73
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Section D-D (Swing, travel left)
201 SWING
201 336
TRAVEL LEFT
XBs
336 332
XAtL
332 335
335 321
A
321
320
RI C
320
332
AM E
261 305 161 163 163
314
TI N
511 C2
521 551
LA
251
261
AtL
As 254
332
BtL
561
SA
165
NY
Bs
Dr2
264
XAs 204
XBtl
264 204
163
163
View D-D ZX225-1102039
4-74
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Section E-E, L-L (Boom 1, boom 2)
202
BOOM2
336 332
BOOM1 201 336 332
XBb1
XAb2
339 327
335 321
RI C
A
326
332 261
L
511
AM E
161 Dr1
521 CCb 551
332 261
L 158
PbL 523 CRb
TI N
165 307
LCb 551 561 Bb
NY
311
303
SA
163
511 521
LA
Xb2
551 561
161
552 561 513
561
163
320 602
264
261
602
332
XAb1
204
BbR
320 329
158
339 332 336 202
Psp SWING PRIORITY
View E-E
View L-L ZX225-1102040
Shop Manual - June 2013
4-75
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Section F-F (Option, bucket)
259 164 201
201
BUCKET
OPTION
336
336
332
(XBo)
332 335
A
335
321
321
RI C
320
AkR
332 261
163 209
(Ao)
163 511 521
511 521
LA
LCo 551 561
551 561 Bk
SA
971×4 209
NY
(Bo) 163 165
304
Ak
TI N
971×4 165 309 163
261
AM E
604
320 602 332
163
602
264 604
(XAo)
204 164
BkR XBk
BoR
154
264 206 211 561 258
PCk View F-F
4-76
Shop Manual - June 2013
ZX225-1102041
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Section G-G (Arm 1, arm 2)
201 201
336
336
332 XBa1
332 335
XBa2
335
321 320 257
Dr3
RI C
332
A
321
AR
261
AM E
L
163 165 162
TI N
152 165 162 152 302 511 521
LA
551 561
332 261 306 158
CRa
513 523 561 552 251
LCAT2
256 551 561
R2
NY
163
L
320
521
SA
511
165 163 264
264
602 BaR 205
XAa2
XAa1
204 View G-G ZX225-1102042
Shop Manual - June 2013
4-77
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Section H-H (Bypass cut 1, bypass cut 2)
169 162 152 158 154 164 152 162 162 152 164 154 158 152 162 164 154 169 612
PCV2
RI C
PCV1
310
203 333 331 372 373 337 331 262
AM E
XBp2
165
165
SA
NY
LA
TI N
View H-H
310
4-78
Shop Manual - June 2013
162 152
A
612
(XBp1)
163 262 331 337 373 372 331333 203
ZX225-1102043
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Mounting NO. torque (N·m)
Mounting NO. torque (N·m)
Part name
Q’ty
101
BLOCK, valve A
1
308
102
BLOCK, valve B
1
13~17
151
PLUG
34~39
152
220~250
Part name
Q’ty
1
3
310
SPOOL, bypass cut
2
PLUG
7
311
SPOOL, swing priority
1
153
PLUG
3
320
SPRING
9
69~78
154
PLUG
6
321
SPRING
8
7.4~9.8
156
PLUG, orifice
3
322
SPRING
1
7.5~10
158
PLUG
5
323
SPRING
1
10~14
159
PLUG
3
326
SPRING
1
161
O-RING
3
327
SPRING
1
162
O-RING
7
329
SPRING
1
163
O-RING
21
331
SPRING SEAT
4
164
O-RING
7
332
SPRING SEAT
22
165
O-RING
14
333
FLANGE SOCKET
2
166
O-RING
1
335
STOPPER
9
168
O-RING
3
336
FLANGE SOCKET
11
169
O-RING
2
337
STOPPER
2
201
COVER, spring
9
339
STOPPER
2
202
COVER, spring
2
372
SPRING
2
203
COVER, spring
2
373
SPRING
2
204
COVER, spool
7
511
VALVE, cone
8
205
COVER, spool
1
512
VALVE, cone
2
206
COVER, spool
1
513
VALVE, cone
2
RI C
AM E 16~18
TI N
LA
NY
A
309
SPOOL ASS’Y, travel straight SPOOL, option
16~18
1
FLANGE
2
514
VALVE, cone
2
210
PLATE
1
521
SPRING
10
211
PISTON
1
522
SPRING
2
49~65
251
2
523
SPRING
2
9.8~14
252
VALVE, logic control OPTION ASS’Y, lock valve VALVE GP, swing logic
2
541
BALL
1
1
542
SPRING SEAT
1
1
543
SPRING
1
1
25~29
550
PLUG
1
258
VALVE GP, arm 2 logic CHECK VALVE ASS’Y, arm regeneration PLUG
1
230~260
551
PLUG
11
259
PLUG
1
230~260
552
PLUG
2
261
O-RING
11
130~150
553
PLUG
2
SA
209
254 256 69~78
257
Shop Manual - June 2013
4-79
Structure and Function
Mounting NO. torque (N·m) 262
SY195/205/215/225C9 Crawler Hydraulic Excavator
Part name
Q’ty
O-RING
2
Mounting NO. torque (N·m) 561
264
O-RING
9
25~34
273
SCREW, hex, S,H,C
44
98~120
274
SCREW, hex, S,H,C
301 302
Q’ty
O-RING
17
562
O-RING
2
69~78
601
VALVE, main relief
1
4
69~78
602
VALVE, port relief
6
SPOOL, travel
2
120~140
604
VALVE, port relief
2
SPOOL ASS’Y, arm 1
1
69~78
612
PLUG
2
303 SPOOL ASS’Y, boom 1
1
49~65
971
SCREW, hex, S,H,C
8
304
SPOOL, bucket
1
140~180
975
SCREW, hex, S,H,C
10
305
SPOOL, swing
1
977
PLATE name
1
306
SPOOL, arm 2
1
978
PIN
2
307
SPOOL, boom 2
1
SA
NY
LA
TI N
AM E
RI C
A
Part name
4-80
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.6 Hydraulic System, Part 3 4.6.1 Swing motor
L
AM E
RI C
A
NOTE: For the location of the swing motor on the machine, see “Hydraulic equipment layout” on page 4-24.
SH
PB
TI N
IP
PG
PA
DR
LA
M
B
A
1
A: B:
SA
NY
2
ZX215-1002081
Main oil port
1. Relief valve
Main oil port
2. Reverse prevention valve
M: Oil complement port PA: Pressure detection port PB: Pressure detection port
For more technical information about the swing motor, see “Swing motor” on page 3-6.
DB: Lubricating port PG: Brake release port SH: Brake direction port L:
Oil level stick
IP: Gear oil feed port Shop Manual - June 2013
4-81
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
7
RI C
A
6
A 8
AM E
A-A
9
A
LA
4
TI N
5
10
11
NY
3
12
SA
2
13
1
ZX215-1002082
1)
Spacer
6)
Check valve spring
11) Plate
2)
Casing
7)
Check valve
12) Piston
3)
Disc
8)
Oil distribution plate
13) Drive shaft
4)
Brake spring
9)
Cylinder
5)
Shell
10) Brake piston
4-82
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.6.2 Swing holding brake ● Port PG is connected with the pilot gear pump directly, and a pressure of 3.9MPa is maintained.
A
M a
Pump
RI C
1
Main valve
7
PX PG
SH
ZX215-1002083
TI N
5
AM E
6
LA
● Port SH is connected with port PX of the main valve. Once any movement other than travel is applied on the main valve, pressure will be generated at port PX, and port PG is interconnected with chamber a beneath piston 7. The pressurized oil compresses brake spring (1) and pushes the brake piston up. Disc (5) is separated from plate (6), releasing the brake.
NY
M
a
SA
Pump
1 Main valve
7
PX PG
6 SH 5
ZX215-1002084
● Otherwise, no pressure is generated at port PX, and port PG is shut off from chamber a beneath piston (7). Brake piston (7) is pushed down by brake spring (1). Disc (5) and plate (6) are pushed together, and the brake is applied. Shop Manual - June 2013
4-83
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.6.3 Relief valve portion NOTE: For the location of the relief valve on the swing motor, see “Swing motor” on page 4-81. Structure ● The relief valve portion consists of relief valves (1) and (2), check valves (3) and (4).
RI C
SA
NY
LA
TI N
● In order to avoid the motor damage, the relief valve relieves the abnormally high pressure to port (M) from the motor outlet side (high-pressure side) of the motor.
AM E
● When the machine is in the swing holding mode, control valve (5) closes the motor outlet circuit, but the motor rotation continues due to inertial force. The motor output, therefore, is abnormally increased, resulting in motor damage.
A
Function
4-84
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Operation 1. When swing begins (suppose pressurized oil enters Port A)
From port M
1
2
● When the swing control lever is operated for right swing, pressurized oil from the pump is supplied to port (A) via control valve (5).
RI C
A
● The pressure on port (A) rises, the starting torque is generated in the motor, and the motor is activated.
3
● The pressurized oil from the outlet port of the motor passes from port (B) through the control valve (5) and returns to the tank.
C
A
AM E
2. When swing stops
4
● When the swing control lever is neutralized, the supply of pressurized oil from the pump to port (A) is cut off.
B
5 ZX215-1002085
TI N
From port M 1
2
LA
● The pressurized oil from the motor outlet can't return to the tank since the return circuit to the tank is closed from control valve (5). Thus, pressure at port (B) rises.
NY
● Swing resistance is generated on the motor and hence the brake starts working.
4
3
SA
● Pressurized oil will be relieved when the pressure on port (B) rises to the set pressure of relief valve (2). ● A high braking torque is applied on the motor, thereby stopping the motor.
C A
B 5 ZX215-1002086
● When relief valve (2) is being actuated, the relieved pressurized oil and the pressurized oil from port (M) are fed to port (B) via check valve (4). ● Above prevents cavitation on port (B).
Shop Manual - June 2013
4-85
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.6.4 Reverse prevention valve 4.6.4.1 Operation drawing NOTE: For the location of the reverse prevention valve on the swing motor, see “Swing motor” on page 4-81. T1
7
6
2
3
4
TI N
1
B
AM E
T2
RI C
A
A
5
LA
Swing motor
T
A
B
Swing control valve
1)
Valve body
2)
ZX215-1002087
Spool (B side)
Spool (A side)
6)
Spring (B side)
3)
Spring (A side)
7)
Plug
4)
Plug
4-86
SA
NY
5)
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.6.4.2 Explanatory drawing of effects
With reversal prevention valve :Without reversal prevention valve Reversal pressure
Containment pressure
Reversal pressure
RI C
Pressure MB
A
Pressure MA
1st reversal
Brake
Start
AM E
2nd reversal
Motor speed
Reversal
TI N
Time
Outline
LA
● Inertia of the swing body, the backlash and rigidity of the machinery system, and the compression of the hydraulic oil all may cause the machine to shake during swing operation. The reverse prevention valve is designed to reduce this effect. The valve contributes in preventing collapsing of load when the swing is stopped and also contributes in reducing cycle time (enhances the positioning performance, enabling you to proceed to the next work quicker than ever).
ZX215-1002088
A c e
D4 a D3
SA
NY
T
D1 d Notch D2 % b f 7 ZX215-1002089
Shop Manual - June 2013
4-87
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Operation 1. When port (B) brake pressure is generated ● Pressure (MB) is conducted to chamber (d) via the notch. The pressure compresses spring (6) by use of the difference in areas of circles (D1 > D2) of spool (5) and moves spring (6) to the left side. Port (B) and chamber (e) will be interconnected. Since pressure (A) is lower than the set pressure of spring (3), spool (2) does not move and the pressurized oil is stopped by spool (2). Thus the braking force is ensured.
$ T ' D '
RI C
A
F H
%
E I
AM E
' G Notch '
2. When motor is stopped
ZX215-1002090
A T
a 2
3
NY
LA
TI N
● The motor rotation is reversed by the closing pressure generated at port (B). (1st time: reverse rotation) Reversing pressure is generated on port (A). Pressure (A) is conducted to chamber (a), and spool (2) moves spring (3) to the right side, and A and B is interconnected. At this time, b is interconnected with f via the orifice on spool (5), and reversing pressure on port A is bypassed to port T, preventing the second reverse rotation.
T
B b f T ZX215-1002091
SA 4-88
5 d
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.6.5 Center swivel joint NOTE: For the location of the central swivel joint on the machine, see “Hydraulic equipment layout” on page 4-24. Z 8
13
9
10
6
11
F 4
D
AM E
C
RI C
12
5
H
A
7
B
A
3
LA
1
TI N
2
NY
H
H-H
G1
SA
F1
G D1
A1 B1 C1 Z ZX215-1002092
1)
Swing shaft
8)
Plug (ZG3/4)
2)
Dust seal
9)
Plug (ZG1/4)
3)
O-ring
10) Cover
4)
Swing body
11) Spacer
5)
Rotating seal φ100x5
12) Gasket
6)
Gasket
13) Gasket
7)
Retaining ring φ 90 Shop Manual - June 2013
4-89
Structure and Function
B:
From main valve BTR
C:
From main valve ATL
D:
From main valve ATR
A1:
To L. travel motor port (P1)
B2:
To R. travel motor port (P2)
C3:
To L. travel motor port (P2)
D4:
To R. travel motor port (P1)
G:
To swing motor port DB
G1:
From travel motor final drive assembly oil drain port (D1,D2)
F:
From solenoid valve port A2
F1:
To travel motor reducer Hi/Lo speed switching port (P)
RI C
From main valve BTL
SA
NY
LA
TI N
AM E
A:
A
SY195/205/215/225C9 Crawler Hydraulic Excavator
4-90
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.6.6 Travel motor Model: TM40VD-A-99/163-1
A
NOTE: For the location of the travel motor on the machine, see “Hydraulic equipment layout” on page 4-24.
RI C
D1 A P1
AM E
P
P2
B D2
P5
TI N
WX215-1204014G
Duo speed pilot hose port
P1:
Pressure detection port
P2:
Pressure detection port
P5:
Parking brake release port
NY
LA
Ps:
D1:
Drain port
D2:
Plug
A:
Main oil port
B:
Main oil port
Working condition
Gear ratio
SA
Reduction gear
Hydraulic motor
Speed 1
Speed 2
49.95
Theoretical output torque
(kgf.m)
Max. 4650
4535
2767
Theoretical output speed
(r.p.m)
Max. 60
28
45.9
Displacement
(cc/rev)
Max. 174.7
162.9
99.4
(kgf/cm2)
Max. 350
Theoretical speed
(r.p.m)
Max. 2800
Flow
(l/min)
250
(kgf/cm2)
20~70
(kgf.m)
Min. 50
(kgf/cm2)
8.2
Continuous pressure
Duo speed control pressure Braking torque Brake release pressure
350 1400
2294 228
1~3L/min (above 365) 15L/min (above 420)
Relief valve activation pressure
Shop Manual - June 2013
4-91
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Explosive view
37 46 44 22
34
20 6
23 24 14
25
8
29
10
31 32
52 51
2
4
58 57 59 13 16
53
1)
27
30
15
54 12 55 56
49
33
5
15 18 17
21
19 42
9 7 15 4
21
35
14
47 48
RI C
6
42
A
1 8
41
50
40
AM E
10
11 3
43
15
7
28 9 3
Flange, rear
16) Plug
2) H5 balance valve spool
17) Spool
3)
36
TI N
5
38
39 45 26
WX215-1204013G
46) Ball bearing
32) Spheric bush
47) Spring
18) Spring
33) Timing plate
48) Piston
Plug
19) Ball
34) Parking piston
49) Stopper
4)
D type block
20) Orifice
35) Spring
50) Pivot
5)
Check plug
21) O-ring
Check valve
22) Filter
36) C y l i n d e r b l o c k spring
51) Plunger
6) 7)
Spring
23) Name plate
37) Friction plate
53) Valve body
8)
Stop spring
24) Rivet
38) Spacer
54) Washer
9)
O-ring
25) Plug
39) Oil seal
55) O-ring
26) Drive shaft
40) O-ring
56) O-ring 57) Shim
12) Socket head bolt
27) P - t y p e s w a s h plate
41) O-ring 42) Parallel pin
58) Spring
13) O-ring
28) Cylinder block
43) Washer
59) Piston rod
14) Plug
29) Piston
44) Washer
15) Plug
30) Stopper
45) Ball bearing
NY
SA
10) O-ring
11) Parallel pin
4-92
LA
31) Baffle
Shop Manual - June 2013
52) Piston seal
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Model: MAG-170VP-3400E NOTE: For the location of the travel motor on the machine, see “Hydraulic equipment layout” on page 4-24.
Ps
Tin
Dr
1
P1
A
AM E
RI C
A
Pm1
Ps:
Duo speed pilot hose port
2
P2
B ZX215-1002132
A. Mounting surface with sprocket
LA
Pm1: Pressure detection port
Pp
TI N
Pm2
B. Mounting surface with undercarriage 1. Mounting hole with sprocket
Tin:
Motor case inner oil port
2. Mounting hole with undercarriage
Pp:
Brake release port
Dr:
Oil drain port
P1:
Main oil port
P2:
Main oil port
SA
NY
Pm2: Pressure detection port
NOTE: For more technical information about the travel motor, see “Travel motor” on page 3-7.
Shop Manual - June 2013
4-93
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Connected to sprocket
Mounted on the undercarriage 5
4
2-1
1-4
1-3
A
Piston motor shaft
AM E
RI C
1-5
1-6
1-2
3
2-4
2-3
4-94
2-2
2-6
2-5 ZX215-1002093
SA
NY
LA
TI N
1-1
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.6.6.1 Operation of components Counterbalance valve Function
● This valve can serve as a shuttle valve for high pressure selection to release the brake under its own pressure.
RI C AM E
● The counterbalance valve and the relief valve constitute the braking circuit. The braking circuit applies braking force onto the rotating motor and stops the motor gradually.
A
● When external load makes the rotating speed of the piston motor faster than the rated rotating speed of supplied delivery, this valve controls the speed of the motor and prevent over-speed of the motor in relation with the supplied delivery.
SA
NY
LA
TI N
● The structure of a standard counterbalance valve is shown as below. The following information describes the operating principle of a standard counterbalance valve.
Shop Manual - June 2013
4-95
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
A. Stopped state pressure is generated at port P1 and port P2. The motor is not rotating.
● When the main valve is neutralized (motor stopped), port M1 and port M2 are shut off by spool (1) and check valve (2) since no
RI C
A
8-1
8
8-2
Circuit C1
AM E
Circuit B Circuit C2
M2
M1
Orifice D1 Damper chamber A1
Orifice D3 Damper chamber A2
Spring chamber 1 P1
7-1
P2
3
4-1
2-1
1
2-2
4-2
5-2 ZX215-1002094
SA 4-96
6-2
7-2
NY
5-1
Spring chamber 2
LA
6-1
TI N
Orifice D4 Orifice D2
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
B. When the motor is activated damper chamber (A1) via orifice (4-1) and check valve (5-1). The force generated in this way pushes spring (7-2) on the other side and moves piston (1) to the right. At this time, return oil from port M2 passes through circuit of the notch on the periphery of piston (1), and through port P2 when pressure is generated at port M2, and enters the tank via the main valve finally. The motor is activated at this time.
AM E
RI C
A
● When hydraulic oil from the main pump enters port P1 of the counterbalance valve, spring (3) is pushed to the left by check valve (2-1), opening circuit C1. The hydraulic oil enters the piston motor via port M, trying to make the motor rotating. At the same time, return oil from the piston motor enters the counterbalance via port M2, but it is stopped by check valve (2-2). The output pressure of the main pump increases as a result, and the hydraulic oil works on the inside of spring chamber (1) and
8-1
TI N
8 8-2
Circuit C1
LA
M1
Orifice D1 Damper chamber A1
Circuit B Circuit C2 M2
Orifice D3 Damper chamber A2 Orifice D4
Orifice D2
NY
Spring chamber 2
Spring chamber 1
P2
P1
6-2
SA
6-1
7-2
7-1 5-1
3
4-1
2-1
1
2-2
4-2
5-2 ZX215-1002095
Shop Manual - June 2013
4-97
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
RI C AM E
SA
NY
LA
TI N
● When the engine runs at an excessively high speed because of external force applied on it, the motor may lose control. At this time, port P1 serves as the inlet side, and the pressure drops. Pressure in spring chamber 1 and damper chamber A1 also drop. As a result, pison (1) moves to the left under the force of spring (7-2), closing circuit B. Circuit at the suction side is also closed at the same time when the circuit at return side is closed. When circuit B is closed, pressure at port P1 rises due to hydraulic oil from the main pump, moving piston (10 to the right again. In this way, when external load generates pump effect, slight movement of piston (1) keep circuit B open. The rotation speed of the motor keeps in line with fuel supply of the main pump, and the motor will not lose control because of the vacuum in the hydraulic system.
A
C. Counterbalance function
4-98
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
D. Braking of motor braking force of motor rotation. When the pressure at port M2 reaches the set pressure of relief valve (8), cone valve (8-1) at port M1 overcomes the force of spring (82) and moves to the left, and hydraulic oil flows the port M1. In this way, the impacting force due to inertia at port M2 is under control, and vacuum at port M1 is avoided.
AM E
RI C
A
● The counterbalance valve and the relief valve forms the braking circuit. When the main valve is neutralized position, hydraulic oil from the main pump is cut off, and pressure at port P1 and P2 is the same. As a result, piston (1) moves to the neutral position, and the opening area of circuit B decreases. At the same time, because of the inertia of external force, the motor does not stop rotating (pump effect), and pressure at port M2 rises and serves as the
8-1
TI N
8 8-2
Circuit C1
Circuit B Circuit C2 M2
Orifice D3
LA
M1
Orifice D1 Damper chamber A1
Damper chamber A2 Orifice D4
Orifice D2
NY
Spring chamber 2
Spring chamber 1
P2
P1
6-2
SA
6-1
7-1
5-1
7-2 3
4-1
2-1
1
2-2
4-2
5-2 ZX215-1002096
Shop Manual - June 2013
4-99
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
E. Shuttle valve function for high pressure selection
A
ber E to release travel brake. In addition, piston (1) moves to neutral position, as shown in fig 5 when motor stops. Circuit D is closed and drain circuit F of motor body is connected. Hydraulic oil in travel braking cylinder chamber E is conducted to the drain circuit of motor body, and travel brake is applied.
RI C
● The counterbalance valve can function as a shuttle valve to release travel brake. When hydraulic oil is fed to port P1, piston (1) moves to the right, as shown in fig. 4. At this time, drain circuit F of motor body is cut off, and circuit D leading to cylinder chamber E for travel braking is connected. Hydraulic oil flows to circuit G via the orifice, and enters travel brake cylinder cham-
1
AM E
Circuit D Circuit D
Orifice
SA
NY
1
Circuit F Circuit D
Circuit F
TI N
Circuit G
Circuit G
LA
Circuit F Circuit D
Cylinder chamber E
ZX215-1002097
Circuit D Circuit D
Orifice Circuit G
Circuit F Circuit G Cylinder chamber E
ZX215-1002098
4-100
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Operation of parking brake
1) When travel begins ● As the travel lever is operated, pressurized oil from the pump activates counterbalance valve spool (10), opens the parking brake circuit, and flows to chamber A of brake piston (12). Pressurized oil overcomes the force of spring (11) and pushes piston (12) toward the left.
A RI C AM E
● Since the pushing force to plate (13) and disc (14) disappears, plate (13) is separated from disc (14) and the brake is released.
10
11
14
13 12
A
Travel control valve
M 22
ZX215-1002099
TI N
2) When travel stops
10
SA
NY
LA
● As the travel lever is placed in neutral, counterbalance valve spool (10) returns to the neutral position and closes the parking brake circuit. The pressurized oil in chamber (A) of brake piston (12) passes through the orifice of the brake piston and is drained to the motor case. Brake piston (12) is pushed to the right by spring (12). Plate (13) and disc (14) are pushed together, and the brake is applied. As brake piston (12) returns, flow of pressurized oil is reduced with slow return valve (22). The time delay will be set to activate the brake only after the machine has stopped.
Travel control valve
11
Shop Manual - June 2013
14
13 12
A
M 22
ZX215-1002100
4-101
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Brake valve operation ● The brake valve consists of suction safety valve (8A) and counterbalance valve (18). Functions and operations of respective components are described below.
Travel control valve PA
PB
18
RI C
A
8A
1) Counterbalance valve and check valve
MB
AM E
MA
ZX215-1002101
TI N
Function
SA
NY
LA
● When the machine is travels downhill, the weight of the machine tends to make the travel speed faster than the motor speed. If the machine travels with the engine at low speed, the motor may rotate at zero load, resulting in run away and inviting a very dangerous situation. These valves are used to avoid such a situation by controlling the machine to travel as per the engine speed (pump delivery).
Operation when pressurized oil is supplied
PA
PB
8B
8A
19
● Operating the travel lever conducts the pressurized oil from the control valve to port (PA). The pressurized oil opens suction safety valve (8A) and then flows to motor outlet port (MB) via motor inlet port (MA). The motor outlet side is closed by suction safety valve (8B) and spool (19), so the pressure at the supply side rises.
4-102
Travel control valve
Shop Manual - June 2013
MA
MB ZX215-1002102
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
● The pressurized oil on the supply side flows to chamber (S1) via orifice (E1) and orifice (E2) of the spool (19). As the pressure in chamber (S1) goes above the spool selector pressure, spool (19) is pushed toward the right. Port (MB) and port (PB) are connected, the motor outlet port side opens and the motor starts rotating.
Travel control valve
PB
PA
RI C
19
A
S1
MA
MB
Operation of brake during downhill travel
ZX215-1002103
Travel control valve
PB
PA
20
S1
19 MA
MB
E1 E2 ZX215-1002104
SA
NY
LA
TI N
● If the machine goes out of control while travelling downhill, the motor will be caused to rotate without load to decrease the inlet side oil pressure. Pressure in chamber (S1) is released via orifices (E1) and (E2). As the pressure in chamber (S1) goes below the spool selector pressure, spool (19) is returned to the left by spring (20) and outlet port (MB) is throttled. The pressure at the outlet port side rises, generating rotation resistance on the motor to prevent the machine from losing control. On the other hand, the spool moves to a position where the pressure on outlet port (MB) can be balanced against the machine's own weight and the inlet port pressure. Oil flow from the outlet circuit is reduced to ensure the travel speed corresponded to the pump delivery.
AM E
E1 E2
Shop Manual - June 2013
4-103
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
2) Safety valve Function
RI C AM E
Operation
A
● When the machine travel is stopped (or it is travelling downhill), the counterbalance valve closes the inlet and outlet circuits of the motor. Since the motor is rotated by inertial force, pressure in the motor outlet port side is abnormally increased, potentially resulting in damages on the motor and piping. The safety valve releases this abnormal pressure to the inlet port side of the motor in order to prevent damages to the equipment.
Travel control valve
1. When travel is stopped (or when travelling downhill) (Right swing)
20
TI N
● Reduction of the pressure at motor inlet (PA) decreases the pressure in chamber (S1). When it drops beyond the spool switching pressure, the spool is returned to the left by spring (20), reducing the pressure at outlet passage (B1). At this time, the motor continues rotating due to its inertial force, thus pressure on the outlet port (MB) is increased.
PB
PA
LA
S1
MA
MB
A1
NY
B1
ZX215-1002105
SA
● When the pressure rises above the set pressure of the suction safety valve (8A), the poppet opens. The pressurized oil passes through notch (A1) of spool (19) into chamber (MA) of the circuit at the opposite side. Spool
MB
MA ZX215-1002107
4-104
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
2. When starting travel (or when traveling at a constant speed)
Travel control valve
PB
PA
● As the travel lever is operated, the pressurized oil from the pump moves spool (19) toward right. The passage to the suction safety valve functions as a circuit which passes through notch (B2) of spool (19), producing large differential pressure. The pump pressure rises, providing a large tractional force to the valve.
8A
A
S1
RI C
19
MA
B2 ZX215-1002106
LA
TI N
● The structure of the relief valve is shown in the right figure. This valve is area difference and direct flow type. It has impact damping function during starting and braking.
MB
AM E
E1
3) Relief valve
8B
ZX215-1002108
NY
A. Operation principle and function
2-9-2
2-9-5
SA
● When the main valve makes the motor to start or brake, front pressure of cone valve (2-9-2) rises above the set pressure and the force of spring (2-9-5), and moves cone valve (2-9-2) to the right and off the valve seat. Pressurized oil in the front of cone valve (2-9-2) is bypassed to the low pressure side. The impact due to inertia energy at the high pressure side is put under control and vacuum is prevented from occurring at the low pressure side through bypassing pressurized oil to the low pressure side.
2-9-3
Shop Manual - June 2013
ZX215-1002109
4-105
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
B. Damping function Area S2
2-9-5
Spring chamber D
RI C
2-9-3 Area S1 2-9-9
A
2-9-2
LA
TI N
AM E
ZX215-1002110
SA
NY
Pressure
● When the relief valve begins to function, damping piston (2-9-9) moves to the left. As a result, low pressure is maintained in spring chamber D. At this time, the loaded area of cone valve (2-9-2) is S1, and it is much larger than the normal set loaded area S1-S2 of the relief valve. So, when damping piston (2-9-9) is moving, the functional pressure of relief valve is maintained at 1/3 of normal set pressure in order to absorb the impact at the high pressure circuit side due to inertia energy. When the movement of damping piston stops, pressure in spring chamber D rises. Pressure at both side of cone valve (2-9-2) is the same, and the relief valve is working at normal set pressure. In this way, the relief valve reduces the impact during motor start and brake by a two-stage action to provide excellent performance.
Damping method
Time ZX215-1002111
4-106
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.6.7 Valve control system
AM E
RI C
9
A
8
7 6 1
2
10
5
3
5
TI N
4
6
9
11
12
8
3
10
LA
13
4
7
NY
2
SA
11
1
12
Shop Manual - June 2013
ZX215-1002112
4-107
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Control lever position Travel PPC valve
(1) HOLD
2.
L. travel control lever
(2) Boom UP
3.
R. travel control lever
(3) Boom DOWN
4.
Right PPC valve
(4) Bucket DUMP
5.
Right joystick
(5) Bucket DIG
6.
Accumulator
(6) HOLD
7.
Transition block
(7) Arm IN
8.
Hydraulic pump
(8) Arm OUT
9.
Main control valve
(9) Right swing
RI C
A
1.
(10) Left swing
11. Left joystick
(11) Neutral
12. Left PPC valve
(12) Reverse travel
AM E
10. Solenoid valve
SA
NY
LA
TI N
(13) Forward travel
4-108
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.6.8 Pilot valve 4.6.8.1 Work equipment and swing pilot valve P3
P2
A T
2
3
RI C
A
P
P
AM E
1
4
P4
A
19~22Nm
SA
NY
LA
TI N
64~73.5Nm
P1
ZX215-1002113
P: P1: P2: P3: P4: T:
From pilot pump relief valve L.H. Pilot valve: Arm OUT L.H. Pilot valve: Arm IN L.H. Pilot valve: Swing LEFT L.H. Pilot valve: Swing RIGHT To tank
R.H. Pilot valve: Boom DOWN R.H. Pilot valve: Boom UP R.H Pilot valve: Bucket DIG R.H. Pilot valve: Bucket DUMP
Shop Manual - June 2013
4-109
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
6 7
AM E
RI C
8
A
5
4
9
TI N
3
A-A
ZX215-1002114
1)
Plunger
6)
Nut (for lever connection)
2)
SA
NY
1
LA
2
10
Metering spring
7)
Joint
3)
Centering spring
8)
Plate
4)
Piston
9)
Retainer
5)
Disc
10) Valve body
4-110
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Operation 1. When in neutral ● Ports (A) and (B) of the control valve and ports (P1) and (P2) of the pilot valve are connected to drain chamber (D) via orifice (f) in plunger (1).
D
2. Fine control (Neutral to fine control)
A
f
T
● When piston (4) is pushed by disc (5), retainer (9) is pushed, plunger (1) is also pushed by metering spring (2), and moves down.
AM E
P
Pilot pump
P1
M
A
P2
Control valve
M
TI N
● When orifice (f) is shut off from drain chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP). Pilot pressurized oil of the control pump is led to port (A) from port (P1) via orifice (f). When the pressure at port (P1) becomes higher, plunger (1) is pushed back and orifice (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1). As a result, plunger (1) moves up and down until the force of metering spring (2) is balanced with the pressure at port (P1).
RI C
1
B
LA
ZX215-1002115
f
T
1
SA
NY
● The relationship of the position of plunger (1) and body (10) [orifice (f) is in the middle between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) contacts plunger (1). Metering spring (2) contracts in proportion to the stroke of the control lever. Pressure at port (P1) also rises in proportion to the stroke of the control lever. In this way, the control valve spool moves to a position where the pressure of chamber (A) (same as pressure at port (P1)) and the force of the return spring of the control valve spool are balanced.
D
P
Pilot pump
A
P1
M
P2
Control valve
M
B ZX215-1002116
Shop Manual - June 2013
4-111
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
3. During fine control (When control lever is returned) ● When disc (5) starts to return, plunger (1) is pushed up by the force of centering spring (3) and the pressure at port (P1). f
T
A
1
● If the pressure of port (P1) is lowered excessively, plunger (1) is pushed down by metering spring (2).
RI C
● Because of this, orifice (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released.
D
P
● Orifice (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP). Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position.
Pilot pump
AM E
P1
f1
P2
PP
M
A
Control valve
M
B ZX215-1002117
4. At full stroke
LA
TI N
● When the spool of the control valve returns, the oil in drain chamber (D) flows in from orifice (f) in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to replenish the chamber with pressurized oil.
NY
● Disc (5) pushes down piston (4), and retainer (9) pushes down plunger (1).
D f
T
1
SA
● Orifice (f) is shut off from drain chamber (D), and is interconnected to pump pressure chamber (PP). ● Therefore, the pilot pressure oil from the self pressure reducing valve passes through orifice (f) and flows to chamber (A) from port (P1) to push the control valve spool. ● The oil returning from chamber (B) passes from port (P2) through orifice (f) and flows to drain chamber (D).
4-112
P
f1 Pilot pump
A
Shop Manual - June 2013
P1
M
P2 PP
Control valve
M
B ZX215-1002118
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.6.8.2 Travel PPC valve
A
A
RI C
T
AM E
T
P
P
A
P5
P1
2
LA
P2
P6
TI N
P5
3
SA
NY
4
1
P4
P:
From pilot pump
P3 ZX215-1002119
P4: R.H. forward
P1: L.H. reverse
P5: Travel signal
P2: L.H. forward
P6: Travel signal
P3: R.H. reverse
T:
To tank
Shop Manual - June 2013
4-113
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
37~30Nm
B
65~45Nm 1
A
8~6Nm
RI C
2
3
AM E
4 5 6 C
C 2，4
TI N
7
1，3 B
NY
LA
13~11Nm
B-B
SA
C-C
8~6Nm ZX215-1002120
1)
Plate
5)
Centering spring
2)
Body
6)
Metering spring
3)
Piston
7)
Valve
4)
Collar
4-114
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Operation 1. When in neutral ● Ports (A) and (B) of the control valve and ports (P1) and (P2) of the Pilot valve are connected to drain chamber (D) via orifice (f) in plunger (1).
D f T
2. Fine control (Neutral to fine control)
● Pilot pressurized oil of the control pump is led to port (A) from port (P1) via orifice (f).
LA
● As a result, plunger (1) moves up and down until the force of metering spring (2) is balanced with the pressure at port (P1).
A A
P2
B
Control valve
ZX215-1002121
5 4 9
D
2 f
T P 1
PP
Pilot pump
SA
NY
● The relationship of the position of plunger (1) and body (10) [orifice (f) is in the middle between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) contacts plunger (1).
RI C P1
TI N
● When the pressure at port (P1) becomes higher, plunger (1) is pushed back and orifice (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1).
1 Pilot pump
AM E
● When piston (4) is pushed by lever (5), retainer (9) is pushed, plunger (1) is also pushed by metering spring (2), and moves down. When orifice (f) is shut off from drain chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP).
P
● Metering spring (2) contracts in proportion to the stroke of the control lever.
P1
P2 10
A
Control valve
B ZX215-1002122
● Pressure at port (P1) also rises in proportion to the stroke of the control lever. ● In this way, the control valve spool moves to a position where the pressure of chamber (A) (same as pressure at port (P1)) and the force of the return spring of the control valve spool are balanced. Shop Manual - June 2013
4-115
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
3. Fine control (When control lever is returned) ● When lever (5) starts to return, plunger (1) is pushed up by the force of centering spring (3) and pressure at port (P1).
5
● Because of this, orifice (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released.
3
D
A
2 f
● If the pressure of port (P1) is lowered excessively, plunger (1) is pushed down by metering spring (2).
T
RI C
P 1 Pilot pump
A
TI N
● Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position.
P1
4. At full stroke
LA
● When the spool of the control valve returns, the oil in drain chamber (D) flows in from orifice (f) in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to replenish the chamber with pressurized oil.
Control valve
B ZX215-1002123
5 4 D
9 f T
NY
● Lever (5) pushes down piston (4), and retainer (9) pushes down plunger (1).
SA
● Orifice (f) is shut off from drain chamber (D), and is interconnected to pump pressure chamber (PP).
P
f’
1 PP
Pilot pump
● Therefore, the pilot pressure oil from the self pressure reducing valve passes through orifice (f) and flows to chamber (A) from port (P1) to push the control valve spool. ● The oil returning from chamber (B) passes from port (P2) through orifice (f) and flows to drain chamber (D). 4-116
PP
P2
AM E
● Orifice (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP).
f’
Shop Manual - June 2013
P1 A
P2
Control valve
B ZX215-1002124
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.6.9 Solenoid valve Pilot valve lock, travel speed, bucket confluence, swing priority
2
3
4
5
T A6
A3
A2
A1
P1
TI N
AM E
A4
RI C
A
1
WX13060401
Travel hi/lo speed solenoid valve
T:
To oil tank
2)
Swing priority solenoid valve
P:
From accumulator and pilot pump
3)
Bucket confluence solenoid valve
A1
To center swivel joint port
4)
Boom to arm priority solenoid valve
A2
To main valve port PsP
5)
Pilot lockout solenoid valve
A3
To main valve port Xbp2
A4
To main valve port PnA2
A6
To pilot valve block P
SA
NY
LA
1)
NOTE: For the location of the solenoid valve on the machine, see “Hydraulic equipment layout” on page 4-24.
Shop Manual - June 2013
4-117
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.6.10 Accumulator
1
A
2
RI C
3
AM E
4
5
2)
Shell
3)
Poppet
4)
Holder
5)
Bladder
6)
Oil port
Specifications Gas capacity: 300 cm³
LA
Gas plug
ZX215-1002126
SA
NY
1)
TI N
6
4-118
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.6.11 Pilot oil filter K 1 K 2
A
型号 压力 精度
RI C
3
5
AM E
4
LA
TI N
6
3
NY
ZX215-1002127
Specifications
Name plate
Max. delivery: 40 L/min
2)
Head cover
Filter fineness: 10 μm
O-ring
Operating pressure: 20 Mpa
Seal
Max. operating pressure: 40 Mpa
5)
Filter
Pressure loss: 0.05 Mpa
6)
Case
Max. allowable pressure difference: 1 Mpa
3) 4)
SA
1)
Specification of inlet/outlet port o-ring: 30×3.1
Shop Manual - June 2013
4-119
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.6.12 Pump oil pressure sensor
1
3
2
A
B
RI C
A
C
4
1)
Pressure connector
2)
Name plate
3)
Connector
4)
Vent hole
AM E
ZX215-1002128
TI N
Function
SA
NY
LA
● This sensor measures pump oil pressure and uses it to control various machine operations. When oil pressure compresses the diaphragm, it deforms and this is detected in the form of electric signals.
4-120
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.6.13 Hydraulic cylinder Boom cylinder
5340±50N·m 544.9±5.1kgm
1
3
RI C
A
2
56.9±10.7N·m 5.8±1.1kgm
AM E
267±35N·m 27.2±3.6kgm
Arm cylinder
1
LA
367±35N·m 37.4±3.6kgm
TI N
2
ZX215-1002129
7900±50N·m 806.1±5.1kgm
3
56.9±10.7N·m 5.8±1.1kgm ZX215-1002130
5480±50N·m 559.2±5.1kgm
1
3
SA
2
NY
Bucket cylinder
56.9±10.7N·m 5.8±1.1kgm
267±35N·m 27.2±3.6kgm
ZX215-1002131
Shop Manual - June 2013
4-121
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
100 hours greasing Unit: mm
3
Standard size
Boom
85
Arm
95
Bucket
80
Boom
80
Arm
80
Bucket
70
Boom
70
Arm
80
Clearance between piston rod and bushing
Clearance between piston rod support pin and bushing
Clearance between cylinder bottom support pin and bushing
Bucket
70
Check item
LA
500 hours greasing No.
NY
Cylinder Clearance between piston rod and bushing
SA
1
2
3
Clearance between piston rod support pin and bushing
Clearance between cylinder bottom support pin and bushing
4-122
Tolerance Shaft -0.036 -0.090 -0.036 -0.090 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076
Hole +0.222 +0.047 +0.222 +0.047 +0.258 +0.048 +0.246 +0.200 +0.246 +0.200 +0.246 +0.200 +0.246 +0.200 +0.246 +0.200 +0.246 +0.200
Standard size
Boom
85
Arm
95
Bucket
80
Boom
80
Arm
80
Bucket
70
Boom
70
Arm
80
Bucket
70
Standard clearance
Clearance limit
0.083 – 0.312
0.412
0.083 – 0.312
0.412
0.078 – 0.334
0.434
0.230 – 0.322
1.0
0.230 – 0.322
1.0
0.230 – 0.322
1.0
0.230 – 0.322
1.0
0.230 – 0.322
1.0
0.230 – 0.322
1.0
Replace pin or bushing
Unit: mm Criteria
Tolerance Shaft -0.036 -0.090 -0.036 -0.090 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076 -0.030 -0.076
Replace bushing
A
Cylinder
Remedy
RI C
2
Criteria
AM E
1
Check item
TI N
No.
Hole +0.222 +0.047 +0.222 +0.047 +0.258 +0.048 +0.246 +0.200 +0.246 +0.200 +0.246 +0.200 +0.246 +0.200 +0.246 +0.200 +0.246 +0.200
Shop Manual - June 2013
Remedy
Standard clearance
Clearance limit
0.083 – 0.312
0.412
0.083 – 0.312
0.412
0.078 – 0.334
0.434
0.230 – 0.322
1.0
0.230 – 0.322
1.0
0.230 – 0.322
1.0
0.230 – 0.322
1.0
0.230 – 0.322
1.0
0.230 – 0.322
1.0
Replace bushing
Replace pin or bushing
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.6.14 Work equipment F
D
A
C
E
RI C
G
,
A
B
H
TI N
K
AM E
J
LA
ZX215-1002133
6
SA
NY
1
2
3
A-A
C-C
5
B-B G-G
H-H
E-E
,-,
D-D
F-F
Shop Manual - June 2013
4
J-J
K-K
ZX215-1002134
4-123
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
100 hour greasing Unit: mm Check item
Criteria
Clearance between pin connect1 ing boom and revolving frame and bushing
Standard size
Remedy
Tolerance
Standard clear- Clearance ance limit Hole
Shaft
90
–0.036 +0.140 0.141 ~ 0.211 –0.071 +0.105
1.0
A
No.
Clearance between pin connecting boom and arm and bushing
90
–0.036 +0.174 0.140 ~ 0.345 –0.071 +0.104
1.0
3
Clearance between pin connecting arm and rocker and bushing
70
–0.030 +0.335 0.305 ~ 0.395 –0.060 +0.275
1.0
4
Clearance between pin connecting arm and bucket and bushing
80
–0.030 +0.324 0.300 ~ 0.384 –0.060 +0.270
1.0
5
Clearance between pin connecting linkage and bucket and bushing
80
–0.030 +0.373 0.303 ~ 0.433 –0.060 +0.273
1.0
6
Clearance between pin connecting linkages and bushing
70
–0.030 +0.335 0.305 ~ 0.395 –0.060 +0.275
1.0
Check item
AM E
TI N LA
500 hour greasing
No.
RI C
2
NY
Clearance between pin connect1 ing boom and revolving frame and bushing
Standard size
Unit: mm Criteria
Remedy
Tolerance Shaft
Standard clear- Clearance ance limit Hole
90
–0.036 +0.131 0.110 ~ 0.202 –0.071 +0.074
1.0
Clearance between pin connecting boom and arm and bushing
90
–0.036 +0.166 0.110 ~ 0.237 –0.071 +0.074
1.0
3
Clearance between pin connecting arm and rocker and bushing
70
–0.030 +0.158 0.108 ~ 0.218 –0.060 +0.078
1.0
4
Clearance between pin connecting arm and bucket and bushing
80
–0.030 +0.137 0.104 ~ 0.197 –0.060 +0.074
1.0
5
Clearance between pin connecting linkage and bucket and bushing
80
–0.030 +0.166 0.116 ~ 0.226 –0.060 +0.086
1.0
6
Clearance between pin connecting linkages and bushing
70
–0.030 +0.154 0.104 ~ 0.214 –0.060 +0.074
1.0
SA
2
4-124
Replace
Shop Manual - June 2013
Replace
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Arm dimension
9 11 B
C
A
RI C
12 A
A
19
5
D 6
D
14
10
C 8
LA
A-A
TI N
13
15
7
B-B
16
NY
18
AM E
B
SA
17
4
C-C
D-D
1 3
2
WX13060402
Shop Manual - June 2013
4-125
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Unit: mm SY195/205/215C-9
No.
19
4-126
Tolerance
Standard size
Tolerance
1
φ80
+0.1 0
φ80
+0.1 0
2
107
±0.5 0
107
±0.5 0
3
310
-0.3 -0.8
310
-0.3 -0.8
4
φ90
-0.036 -0.071
φ90
-0.036 -0.071
5
549
±1
549
±1
6
158
±0.8
158
±0.8
7
835
±1
835
±1
8
2,911
±2
2,911
±2
9
2,643
±2
2,643
±2
10
411
±0.8
411
±0.8
11
640
0 -0.5
640
0 -0.5
12
600
—
600
—
13
458
—
458
—
14
1,483
—
1,495
—
15
φ80
—
φ80
—
16
326.5
—
326.5
—
17
φ80
+0.2 0
φ80
+0.2 0
Arm itself
311
—
311
—
When press fitting bushing
325
—
325
—
Min.
1,680
—
1,680
—
Max.
2,800
—
2,800
—
RI C
AM E
TI N
LA
NY
A
Standard size
SA
18
SY225C-9
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Bucket dimension
5
2 A 17
18
A
6
4 16
AM E
1
RI C
3
19 7
TI N
A
8
15
8
SA
NY
15
LA
13
10
14
12 9
11
20
21
22
A-A
Shop Manual - June 2013
WX13060403
4-127
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Unit: mm No.
SY195/205/215C-9
SY225C-9
Tolerance
Standard size
Tolerance
1
457.5
±0.5
457.5
±0.5
2
22
±0.5
22
±0.5
3
91.8°
—
91.8°
—
4
458
—
458
—
5
1,483
—
1,483
—
6
177
—
177
7
45°
45°
8
φ80
9
348.5
10
37
— +0.2 0 +0.2 0 —
11
107
—
12
473.5
—
13
φ23.5
—
14
φ190
15
φ136
16
131
17
125
18
R180
19
R140
20
57
21
326.5
RI C
—
37
— +0.2 0 +0.2 0 —
107
—
473.5
—
φ23.5
—
—
φ190
—
—
φ136
—
—
131
—
—
125
—
—
R180
—
—
R140
—
—
57
—
±0.5
326.5
±0.5
φ80
NY
LA
TI N
AM E
348.5
SA 4-128
A
Standard size
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.7 Air Conditioning System
1
2 3
5
C C
TI N
C
AM E
RI C
A
4
A
NY 2)
6
7
8 ZX215-1002137
SA
1)
B
LA
C C
A. Fresh air
Hot water piping A/C compressor (DENSO.2)
B. Recirculated air
3)
Refrigeration piping
4)
Condenser (SG447750-A040)
5)
Receiver tank (DENSO.4)
6)
Hot water return piping
7)
A/C unit assembly (SG443180-9320)
8)
Air duct
C. Warm air/cool air
Shop Manual - June 2013
4-129
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.7.1 A/C components layout drawing
2 1 3
5
LA
TI N
AM E
RI C
A
4
NY
7
6 ZX215-1002138
Sunlight sensor
5)
Compressor
2)
Control panel
6)
Fresh air sensor
3)
Air conditioning unit
7)
Recirculated air sensor
4)
Condenser
4-130
SA
1)
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.7.2 Control panel
2
3
4
5
RI C
A
1
8
7
CZ205-1203020G
AM E
6
OFF switch
5)
Auto mode switch
2)
Fan speed control switch
6)
Air circulation control switch
3)
Temperature control switch
7)
LCD display
4)
Air outlet mode switch
8)
A/C switch
SA
NY
LA
TI N
1)
Shop Manual - June 2013
4-131
A RI C 3
AM E
FL1
7
8
8
1.25L D 1.256
FURM 20A 1.25R
RLBM 10 15
2RL 1.25RL MR 2G
M 10
10
200W
12
12
RLCH
10 BLCM 3
2
8
13
13
12
FUM 5A
+B 6
14
13
16
SW H OFF ACC ON START 15
16
18
13
19
19
19
13 20
15
3 22
21
22
SSD
16
B G1 G2 ACC M ST
Wiring diagram
12
RLCC RLCD RLBM
16
16
14
17
15
THAM THW THI THF
28 15
8
TI N
3
8
RLCC
10
11
4
BLC
1
G
15
23
27 4 15
20
28
ACM
21
27
M
29
2
M
MRF
25
1
MV1
31 22 32
31
25
26
24 22 26
23
24
25
22
25
24
30
30
M
32
GND
FUCD 15A
RLCD
9
9
ECC 40W 15
SPHL
0.5B
MAM
REC Vz Pt
60A
CMB
RLCH 03
2B
FFE
2
2
1 1
FLZ 40A
02
MCD SPCD M 80W
02
LA
2 5 5
SW 6
RCD RLCH 02
2B
1.25R 0.50
7 7
D1
D2
03
NY
5
1
BAT ACC
4 4
02
2B
0.85B
4
CMB CM 02
02
SA
G
01
1.25B
RLSF
3
06
06
1.25B
9
15
38
32
33
M
26
34
35
10
34 35 35 22
MV2
Shop Manual - June 2013
4-132
SY195/205/215/225C9 Crawler Hydraulic Excavator
Structure and Function
4.7.3 Circuit diagram
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Wire No. Diameter/Color code
Wire color
Wire No. Diameter/Color code
Wire color
Black
0.5VW
Violet+white
Br(R)
Brown
0.5YB
Yellow+black
0.85W
White
0.5WO
White+orange
RL
Red+blue
0.5PB
Pink+black
G
Green
0.5VR
Violet+red
0.5BL
Black+blue
0.5BG
Black+green
0.5R
Red+blue
0.5WY
White+yellow
0.5Y
Yellow
0.5WR
0.5BR
Black+red
0.5BrY
Brown+yellow
0.5BY
Black+yellow
0.5GW
Green+white
0.5LO
Blue+orange
0.5PG
Pink+green
0.5RY
Red+yellow
0.5BW
Black+white
0.5LgR
Light green+red
RI C 0.5GO
Green+orange
0.5Sb
Sky blue
0.5OW
Orange+white
1.25V
Violet
1.25RG
Red+green
1.25RW
Red+orange
0.85GL
Green+Blue
AM E
Brown+white
Name
Code
ACM
A/C amplifier
FUCD
Condenser fuse
RLCH
BAT
Battery
FUM
A/C main fuse
RLSF
BLC
Speed regulating resistor
G
Alternator
SSD
Battery relay
MAM
A/M servo motor
SPCD
Diode
MB
Blower motor
SPHL
Sunlight sensor Condenser pressure switch HI/LO pressure switch
D1
Diode 1
MCD
SW
Switcher
D2
Diode 2
MRF
THAM
External air thermistor
ECC
Compressor clutch
MV1
Condenser motor Internal/External air servo motor Air outlet servo motor
THF
Anti-frosting thermistor
FL1
Fuse
MV2
FRONT outlet servo motor
THI
Internal air thermistor
FL2
Fuse
RCD
Condenser resistor
THW
Water temp. thermistor
FUBM
Blower fuse
RLBM
Blower main relay
RLCC
Compressor relay
RLCD
Condenser relay
SA
D
NY
CMB
Code
White+red
0.5BrW
TI N
Name
LA
Code
A
B
Shop Manual - June 2013
Name Condenser high speed relay Protective relay
4-133
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.7.4 Refrigeration principle 4.7.4.1 Refrigeration cycle diagram
Expansion valve
Cool air
Lo temp\Lo press liquid (Mist)
A Condenser
Hi-temp hi-pres gas
Hi-pres. side
Lo-pres. side
TI N
Compressor
AM E
Out side fresh air
Receiver
Air in cab
RI C
Cooling fan
Blower
Hi temp\Hi press liquid
Lo temp\Lo press gas
Evaporator
Hot air
Hi-pressure portion
ZX215-1002141
LA
Lo-pressure portion
4.7.4.2 Heating cycle diagram
Water valve control
Water pump
Hot air
SA
NY
Radiator
Engine
Blower motor
Internal air
Low tempr water High temp water
4-134
ZX215-1002142
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.7.5 Compressor 3 1
4
2
RI C
A
16
15
AM E
14
LA
12
TI N
13
5
11
10
6
9
8
7
Stator
9)
2)
Front radial bearing
10) Front cylinder block
3)
Thrust bearing
11) Piston
4)
Front radial bearing
12) Front cylinder head
6) 7) 8)
SA
5)
NY
1)
ZX215-1002143
Slipper
Rear cylinder head
13) Shaft seal
Safety valve
14) Main shaft
Rear cylinder block
15) Hub
Swash plate
16) Rotor
Shop Manual - June 2013
4-135
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Operating principle Compressor type: 10S15C. This compressor has 5 plungers in total with a piston on both sides of each plunger. The rotation of the swash plate drives the pistons to move Process1
back and forth and transforms the refrigerant sucked from the evaporator from low temperature and low pressure gas state to high temperature and high pressure state. Process2 HI press.end pipe LO press.end pipe
A
HI press.end pipe LO press.end pipe
RI C
Valve plate
Main shaft and swash plate
AM E
Outlet valve disc
Intlet valve disc
Process6
HI press.end pipe LO press.end pipe
SA
NY
LA
HI press.end pipe LO press.end pipe
TI N
Process3
Process5
HI press.end pipe LO press.end pipe
Process4 HI press.end pipe LO press.end pipe
ZX215-1002144
4-136
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.7.6 Clutch
Stator coil
3)
Snap ring
4)
Ball bearing
5)
Stator
6)
Center piece
1 2 3 4
A
2)
● The electromagnetic clutch is used to transmit moment of torsion. When the engine is operating, the compressor may not be working. The clutch controls the operation of the compressor only when the air conditioner is under refrigerating mode. ● Operating principle
RI C
Rotor
5
6
ZX215-1002145
AM E
1)
SA
NY
LA
TI N
When the A/C switch is turned on, the clutch coil with an electromagnet generates a magnetic field and attracts the metal piece. The stator and rotor of the clutch are engaged and drives the main shaft of the compressor into rotation.
Shop Manual - June 2013
4-137
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.7.8 Condenser
1 4
2
AM E
RI C
A
3
Condenser core
2)
Bracket
3)
Bolt with gasket
4)
Refrigerant inlet
5)
Refrigerant outlet
ZX215-1002146
TI N
1)
5
LA
Function
NY
● The condenser converts high-temperature, high-pressure gas refrigerant (16Kg/cm², about 80°C) to high-temperature and highpressure liquid refrigerant (16Kg/cm², below 60°C) through radiating.
4.7.7 Expansion valve
SA
Evaporator
1)
Spring
2)
Diaphragm
3)
Probe
4)
Needle valve
2 1
Operating principle
3
● Refrigerant from the receiver tank spurts out via the orifice, turns into low-temperature, low-pressure liquid (mist) after expanding, and enters the evaporator. 4-138
Shop Manual - June 2013
4 Reservoir
Compressor ZX215-1002147
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.7.9 Evaporator 1)
Expansion valve
2)
Evaporator
Inlet Outlet
3)
Receiver/dehydrator
4)
Desiccant
Function
RI C
NY
2)
ZX215-1002148
2 1
LA
1)
TI N
4.7.10 Receiver tank
2
1
AM E
● The evaporator is a kind of heat exchanger that looks like a condenser. Hot air in the cab is conducted into the evaporator via the blower motor and undergoes heat exchange with the surface of the evaporator. Heat is absorbed and hot air turns into cold air, which flows into the cab through the air ducts. Evaporator surface absorbs heat→Refrigerant in the evaporator absorbs heat → Refrigerant evaporates . Evaporated refrigerant (gas) is absorbed by the compressor.
A
Operating principle
3
● Temporary storage of refrigerant
SA
● Dehydration of refrigerant 4
● Dust removal from refrigerant ● Measure the volume of refrigerant
ZX215-1002149
Shop Manual - June 2013
4-139
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.7.11 Pressure switch 1)
O-ring
2)
Mobile contact point
3)
Hood
4)
Plug and fixed contact
5)
Spring
6)
Chamber
7)
Diaphragm
Pressure
1 7
2
Function
3
5
AM E
● The pressure switch is installed between the receiver tank and the expansion valve (hi-pressure pipe). It is a combination switch (Hi-Lo pressure combination switch).
RI C
A
6
ZX215-1002150
TI N
● When pressure is excessively high, the compressor stops.
4
LA
● When pressure and temperature is very low, the compressor stops.
Feature
NY
Operating features
SA
DIFF HI pressure operating value Above 0.02 MPa LO pressure operating value
DIFF
ON
0.59±0.2 MPa
OFF 0.196±0.02 MPa
2.94~3.19 MPa
0.196~0.250 MPa
ON MID pressure operating value
4-140
OFF
1.23±0.1 MPa
1.52±0.08 MPa
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.7.12 Fresh air sensor
Service voltage range
4.4~5.6 V
Service temp range
-30~60 °C
Storage temp range
-40~90 °C
Resistance value
1700±85Ω
B constant
3900±195 K
Allowable operating current
1.6 mA (MAX)
8
A
Specification
10
6 4 2
-10
0
AM E
Item
Resistance value
Technical specifications
12
RI C
/K¡
The fresh air sensor is installed beside the condenser or around the fresh air inlet. It measures the temperature of outside air and it is composed of thermistors.
10
20
30
40
AT
ZX215-1002151
WARNING
TI N
4.7.13 Refrigerant
LA
● Obey local material disposal regulations. Never discharge refrigerant directly into the air.
NY
● Refrigerant R134 a is a harmless gas under room temperature. It will change into highly toxic gas when burning.
SA
● Refrigerant getting into eyes may cause blindness. It may cause frostbite if splashed on your skin. 1. General property ● High heat absorption and easy liquefaction ● Non-flammable, nonexplosive ● Stable chemical composition ● Non-toxic ● Non-corrosive ● No hazard to clothing
Shop Manual - June 2013
4-141
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
2. Refrigerant cycle ● After evaporation in the evaporator, refrigerant turns from gas into liquid via the compressor and the condenser, which finishes a refrigerant cycle.
Compress HI press. side(outlet): HI temp\HI press.\Gas Pressure/Temperature:16Kg/cm²ˈapprox. 80ć
A
Absorb heatėEmit cold air
RI C
Compressor IntakeėDischarge
Compressor LO press. side (inlet): LO temp?LO press.?Gas Pressure/Temperature:2Kg/cm²，approx. 8ć Evaporator
Condensor (outlet)˖HI temp?HI pressure?Liquid Pressure/Tempterature˖16Kg/cm²ˈBelow 60ć
Expansion valve Hi pressureėLo pressure Hi tempėLo temp LiquidėMist
TI N
Condensor Via radiating:Gas refrigerantėLiquid refrigerant
AM E
Condensor (outlet): LO temp\LO press.\Mist Pressure/Temperature: 2Kg/cm²ˈapprox. 0~2ć
● Refrigerant cycle principle (pressure - enthalpy diagram)
LA
lgp
Liquefaction completed
NY
Condensing process
Liquid
Expansion throttle
SA
Liquefaction starts Condensor
Throttling point
Expansion valve
Refrigerant cyclic curve
Compressing process
Compressor
Evaporating process Evaporator
Gasification completed
Gas-liquid mixture
h=u+Apv(kJ/kg) UInternal energy pPressure
4-142
VSpecial volume AJoule equivalent
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
3. Feeding of refrigerant ● Filling method and volume: 1) Refrigerant: HFC-134a 2) Feeding volume: 850±50 g (for reference)
AM E
RI C
A
3) Feeding method: Feeding of liquid refrigerant from the low-pressure end is not allowed. If feeding operation fails, discharge the refrigerant that has been fed before refeeding.
TI N
● Inspect the state of the refrigerant in the A/C circulation system through the sight glass:
LA
1) Correct feeding: Foam is hardly observed when the refrigerant is flowing. When engine speed increases from idling to 1500 rpm, foam disappears and the refrigerant turns clear.
ZX215-1002153
Sight glass
Proper filling
NY
2) Over-feeding: No foam can be observed when refrigerant is flowing.
SA
3) Under-feeding: Foam is always observed when refrigerant is flowing.
Shop Manual - June 2013
Inadequate filling ZX215-1002154
4-143
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4. Evacuation
RI C
A
● No moisture shall exit in the air conditioning unit. Refrigerant (R134a) is soluble in water. Very small amount of moisture in the unit can cause the orifice of the expansion valve to ice up, or cause the compressor valve to rust. To avoid such problems, moisture in the system shall be removed before refrigerant is added. To minimize the residual moisture in the system, moisture in the system can evaporate through evacuating.
Step 1: Connect the manifold pressure gauge 1) Close the high-pressure valve (HI) and low-pressure valve (LO) of the manifold pressure gauge.
AM E
Evacuating steps
Valve
Lo-pres.gauge
LO HI LO HI above 750mmHg OFF OFF ON ON
Lo-pres. gauge
Hi-pres. gauge
TI N
2) Connect the hoses (red, blue) to the auxiliary valve of the compressor. Red hose – High pressure side (Mark D)
Hi-pres. valve(ON)
Lo-pres. valve (ON) Green
LA
Blue
S
Vacuum pump (running)
NY
NOTE: Connect the end of the hose with a L to the auxiliary valve of the compressor. If connected inversely, the valve will not open. Besides, do not inversely connect the high-pressure end and the lowpressure end.
SA
3) Connect the green hose to the vacuum pump.
4-144
D
Red
Blue hose – Low pressure side (Mark S)
Shop Manual - June 2013
Compressor ZX215-1002155
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Step 2: Evacuation 1) Open the high-pressure valve (HI) and lowpressure valve (LO) on the manifold pressure gauge. 2) Turn on the vacuum pump and evacuate for about 15 minutes.
RI C Valve
TI N
1) Keep the Hi- and Lo-pressure valve of the manifold pressure gauge under closed state for more than 5 minutes, and make sure the pointer on the gauge does not return to zero.
AM E
Step 3: Air - proof check
A
3) When negative pressure reading on the gauge (degree of vacuum) reaches above 750 mmHg, turn off the vacuum pump and close the Hi-pressure valve and the Lopressure valve on the gauge.
LA
2) If the pointer returns to near zero, a leakage is available somewhere. Check and adjust the pipe joint. Tighten the joint and conduct another evacuating operation until no leakage is detected.
Lo Hi OFF OFF
Wait 5 min. or more Lo-press. gauge returns to 0
Lo-press. gauge
Pointer returns to 0
Tighten pipe joint
SA
NY
ZX215-1002156
Shop Manual - June 2013
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Step 4: Leak check 1) Connect the green hose that is previously connected to the vacuum pump to the fluorine cylinder.
Vent valve Release air
A
Open
Blue
Green
Fluorine cylinder
AM E Lo
Hi Lo-press gauge 2
OFF ON
Lo-pres.valve (OFF)
Lo
Hi
OFF OFF
Open Hi-pres.valve
Cylinder valve (ON)
D S R134a
Compressor
Fluorine cylinder ZX215-1002158
SA
NY
at 1kgf/cm
Lo-pres. gauge reads1kgf/cm2
5) Make necessary repairs (tightening) if leakage is observed.
4-146
ZX215-1002157
Valve
TI N
LA
4) Use a leak detector to check if leakage is available in the cooling system.
R134a
Red
To compressor
3) Add refrigerant until pressure reading on the Lo-pressure gauge is 1kgf/cm² . Hipressure valve of the gauge is open at this time. Close the Hi-pressure valve when feeding is finished.
Hi
OFF OFF
RI C
2) Connect the other end of the green hose to the pressure gauge. Open the valve of the cylinder and press the vent valve of the pressure gauge. (Do not press the valve with naked hand to avoid frostbite caused by refrigerant). Release the air in the hose with the pressure of the refrigerant. (Release the vent valve when you hear a squeezing sound).
Valve Lo
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
5. Refrigerant charging operation ● When evacuation is finished, add refrigerant into the cooling system as per the following instruction:
Performance testing
A
RI C
Pres. gauge
Tighten pipe joint
Air leak check
Add refrigerant
normal
Air leak check
Pres. gauge
Add refrigerant kgf/cm2
Wait 5 min.
Air-proofness check
More than 15 min.
Evacuation ends
Evacuation starts
75cm-Hg or more
(1) Compressor stopped, charge at hi-press end
abnormal
Check leak point
Charge at the hi-pressure side
AM E
(2)Compressor running, add at lo-press end
Valve
1. Remove the green hose of the manifold pressure gauge from the vacuum pump and connect it to the fluorine cylinder.
TI N
2. Loosen the cylinder valve and press the vent valve on the gauge. Use the pressure of the refrigerant to release the air in the hose.
Lo
Vent valve
Open
Loosen this nut Blue
NOTE: Release the vent valve when you hear a hissing sound.
LA
Hi
OFF OFF
Red
Green
R134a
Fluorine cylinder
To compressor
ZX215-1002159
NY
CAUTION
SA
● Do not press the valve with naked hand to avoid frostbite. 3. Open the hi-pressure valve of the manifold pressure gauge and the cylinder valve with the engine stopped. Fill about 600g of refrigerant. 4. Close the hi-pressure valve of the pressure gauge and shut the cylinder valve.
Valve Lo
Hi
OFF ON
Lo-press. valve (OFF)
A cylinder (about 600g)
Lo
Hi
OFF OFF
gDo not operate compressor gDo not open Lo-pressure valve
Open Hi-press. valve
Fluorine cylinder valve (ON)
D S
R134a
ZX215-1002160
Shop Manual - June 2013
4-147
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
CAUTION ● Do not operate the compressor when refrigerant charging is in progress. Otherwise, refrigerant will counterflow and cause the cylinder and hoses to explode.
RI C
A
● Operating the compressor with no refrigerant in the system will cause damage to the compressor.
Charge at the lo-pressure side (refill) 1. Check that the hi-pressure valve of the manifold pressure gauge is closed.
AM E
● Do not open the lo-pressure valve of the manifold pressure gauge; otherwise, the compressor will be damaged.
2. Start the engine.
TI N
Hi-press. valve (OFF)
3. Turn on the A/C unit. Adjust Temperature control switch to minimum.
H I
LA
4. Adjust engine speed to 1300 – 1500 rpm.
Start the engine
5. Open the Lo-pressure valve of the manifold pressure gauge and the cylinder valve. Add refrigerant until no foam is observed through the sight glass.
1300~1500rpm
NY
ZX215-1002161
Valve
SA
Remark:
Manifold pressure gauge reading (for reference): HIGH pressure: 13~17kgf/cm² (when ambient temperature is 30°C)
ON
Manifold pressure gauge
Lo Hi ON OFF
When no foam is observed
Lo-press. gauge (1.5~2.5kgf/cm2) Lo-press. valve (ON)
Lo Hi OFF OFF
Hi-press. gauge (13~17kgf/cm2) Hi-press. valve (OFF) (Never open it)
Fluorine cylinder valve (ON)
LOW pressure: 1.5~2kgf/cm² (when ambient temperature is 30°C).
Fluorine cylinder (never placed upside down)
Compressor running ZX215-1002162
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Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
6. When refrigerant charging is finished, close the Lo-pressure valve of the manifold pressure gauge and the valve of the fluorine cylinder. 7. Check carefully for air leaks with a leak detector.
CAUTION
RI C AM E
TI N
● When engine is running and charging in progress, placing the fluorine cylinder upside down will cause liquid refrigerant to be sucked directly into the compressor and cause liquid compression, resulting in equipment damage.
A
● Opening the Hi-pressure valve of the pressure gauge will cause pressurized gas to counterflow and cause the hoses and the fluorine cylinder to explode, resulting in serious damage.
8. When ambient temperature is low
Valve Lo Hi
LA
When refrigerant charging gets difficult due to low temperature, put the cylinder in warm water (max. 40°C). 9. When ambient temperature is high
SA
NY
When ambient temperature is very high, cool the compressor with an electrical fan.
ON OFF
Lo-pressure valve (ON)
When no foam is seen
Lo
Hi
OFF OFF
Hi-pressure valve (OFF)
Cylinder valve (ON)
Water less than 40°C (Do not use hot water)
Compressor running ZX215-1002163
Shop Manual - June 2013
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Replace the fluorine cylinder When the refrigerant in a cylinder is used up, replace the cylinder as per the following instruction: 1. Close the Hi- and Lo-pressure valves of the manifold pressure gauge.
Handle
Air hose connector
2. Raise the needle and disc plate of the cylinder and remove the empty cylinder.
A RI C
3. Install a new cylinder onto the cylinder valve.
Needle valve
Disc plate
1) Tighten the valve of the fluorine cylinder, and then, loosen it a bit. 2) Open the Lo-pressure valve of the manifold pressure gauge a bit.
AM E
4. Release the air in the hose as per the following instruction:
Gasket
Refrigerant cylinder
ZX215-1002164
LA
TI N
3) Press the vent valve and allow a little refrigerant to come out. Immediately close the valve of the cylinder and the Lopressure valve of the manifold pressure gauge.
Valve Lo Hi
CAUTION
Loose OFF
● Do not press the valve with naked hand to avoid frostbite.
NY
Close the Lo-pressure valve once you hear the hissing sound
SA
5. Turn the handle of the cylinder valve to pierce the cylinder and continue charging operation.
Loosen the valve a bit
Lo-pressure valve Green
Blue Red
To compressor
R-134a
Refrigerant cylinder ZX215-1002165
4-150
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
6. Fault testing with manifold pressure gauge After the engine has been preheated, read the pressure value on the gauge under the following conditions: 1) Temperature at air inlet: 30 – 35°C 2) Engine speed: 1500 rpm
A
3) Fan speed: High
RI C
4) Temperature control: Minimum. 5) Air circulation mode: Recirculation
Gauge reading: Lo-pressure end: 0.15~0.25 Mpa (1.5~2.5 Kgf/cm²)
TI N
Hi-pressure end: 1.37~1.57 Mpa (14~16 Kgf/cm²)
AM E
● Cooling system under normal condition
04
3
02 2 1
4
5
06
6
07
{cmHg kgf/cm2} 8 0 8.5 -50
0
-76
-01
15
05
20
10
5
25
{cmHg kgf/cm2}
08 0
085
25
30 3
0
MPa
-76 35 -01
35 MPa
R134a
SA
NY
2
15
1
7
LA
01
15
05
03
ZX215-1002167
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
● Moisture in the refrigerating system Symptom: Intermittent refrigeration to non-refrigeration
04
07
{cmHg kgf/cm2} 8 0 8.5 -50 0
1 10
7
1
05
25
5
{cmHg kgf/cm2}
15
085
0
MPa
25
30 3
0 08
-76 -01
20
A
06
6
2
2
15
5
-76 35 -01
35
MPa
RI C
3
4
02
01
15
05
03
Symptom
Cause
AM E
ZX215-1002168
Analysis
Remedy
SA
NY
LA
TI N
● When the system is ● Moisture in the system ● Over-saturation of de- ● Replace receiver/ operating, pressure ices up at the expanhydrator. dehydrator at the Lo-pressure sion valve causing ● Moisture in the system ● Remove the moisend unstable (somecircular temporary ices up at the expanture in the system times vacuum, stop. When ice melts, sion valve and hinders through constant sometimes normal) the system becomes the circulation of the pumping. normal again. refrigerating system. ● Add proper volume of new refrigerant.
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
● Insufficient refrigeration Symptom: Insufficient refrigeration
04
5
-76 -01
15
05
5
25
{cmHg kgf/cm2}
0
085
-76
Cause
● Air leaks somewhere in the refrigerating sys● Foam is continuously obtem served via the sight glass
ZX215-1002169
Remedy
● Insufficient ● Check for air leakage with a leak refrigerant in the detector. Make necessary resystem pairs. ● Leak of refrigerant
● Add proper amount of refrigerant. ● When connected with the gauge, if the reading is near zero, set the system under vacuum state after inspection and repair.
SA
NY
LA
● Insufficient refrigeration.
Analysis
TI N
● Pressure at both Hi- and Ho-pressure ends very low
35 MPa
AM E
Symptom
35
-01
MPa
30 3
0 08
25
A
07
{cmHg kgf/cm2} 8 0 8.5 -50 0
10
7
1
20
1
06
6
2
2
15
RI C
3
4
02
01
15
05
03
Shop Manual - June 2013
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
● Defective refrigerant circulation Symptom: insufficient refrigeration
04
07
{cmHg kgf/cm2} 8 0 8.5 -50 0
1 10
7
1
05
25
5
{cmHg kgf/cm2}
15
085
0
MPa
-76
25
30
0 08
-76 -01
20
A
06
6
2
2
15
5
3
35
-01 35 MPa
RI C
3
4
02
01
15
05
03
Symptom ● Pressure at both Hi- and Lo-pressure sides very low
Cause ● Contaminant in the reservoir hinders the flow of refrigerant.
Analysis
● Blocked reservoir
SA
NY
LA
TI N
● Frosting on the piping between parts and reservoir
AM E
ZX215-1002170
4-154
Shop Manual - June 2013
Remedy ● Replace reservoir
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
● Refrigerant not circulating Symptom: Non-refrigeration (intermittent refrigeration)
5 06
6
2
07
{cmHg kgf/cm2} 8 0 8.5 -50 0
10
-01
05
5
15
25
{cmHg kgf/cm2}
0
085
3
Cause
● Vacuum at Lo-pressure side; pressure at Hi-pressure side extremely low
● Moisture or contaminant in the refrigerant hinders the flow of refrigerant.
● Frosting or condensation on the pipes around the expansion valve or receiver/dehydrator
● Air leak at the thermal pipe of the expansion valve hinders the flow of refrigerant.
35
-01
35 MPa
Analysis
● Refrigerant not circulating
ZX215-1002171
Remedy
● Check the expansion valve and ERP. ● Blow the contaminant in the expansion valve or replace the expansion valve if necessary. ● Replace the receiver ● Release internal air and add refrigerant. If air leaks from thermal pipe, replace expansion valve.
SA
NY
LA
TI N
Symptom
-76
AM E
MPa
25
30
0 08
-76
20
1
7
1
2
15
RI C
3 02
01
15
05 4
A
04 03
Shop Manual - June 2013
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
● Over-charging of refrigerant or insufficient refrigeration of condenser Symptom: Insufficient refrigeration
04
07
{cmHg kgf/cm2} 8 0 8.5 -50 0
1 10
7
1
-01
05
25
5
{cmHg kgf/cm2}
15
085
0
MPa
25
30 3
0 08
-76
20
A
06
6
2
2
15
5
-76
35
-01 MPa
35
RI C
3
4
02
01
15
05
03
Symptom
Cause
Analysis
Remedy
● Over-filling of refriger- ● Over-filling of refriger- ● Clean the condenser ant in the system. Reant ● Check the working frigerating performance ● Condenser fins clogged condition of fan moinadequate. ● No foam can be obor fan motor error. tor served via the sight ● Insufficient refrigera● If the two above glass even when tion of condenser items are normal, engine speed drops. check the volume of refrigerant. Add refrigerant.
SA
NY
LA
TI N
● Pressure at both Hiand Lo-pressure sides very high
AM E
ZX215-1002172
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
● Air is observed in the refrigerating system Symptom: Poor refrigeration NOTE: If refrigerant is added with no evacuation operation performed, the following gauge reading will appear:
5 06
6
2
07
{cmHg kgf/cm2} 8 0 8.5 -50 0
10
-01
05
15
30
25
3
-76 35 -01
35
AM E
MPa
ZX215-1002173
Analysis
Remedy
● Air enters the refrigerant system
● Check if compressor oil is contaminated or inadequate.
TI N
● Pressure at both Hi- and ● Air enters the reLo-pressure ends very frigerating system high
LA
● Insufficient evacuation
● Evacuate and add new refrigerant.
SA
NY
● Foam is observed through the sight glass
{cmHg kgf/cm2}
0
085
Cause
● Lo-pressure piping feeling hot
25
0
MPa
Symptom
5
08
-76
20
1
7
1
2
15
RI C
3 02
01
15
05 4
A
04 03
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
● Improper installation of expansion valve/thermal pipe defect (wide opening) Symptom: insufficient refrigeration
04
1 10
7
1
0
06
6
07
{cmHg kgf/cm2} 8 0 8.5 -50 -01
05
5
25
{cmHg kgf/cm2}
15
3
085
-76
0
35
-01
MPa
25
30
0 08
-76
20
A
5
2
2
15
35
MPa
RI C
3
4
02
01
15
05
03
Symptom
● Expansion valve de● Over-filling of fect, or improper instalrefrigerant in lation of thermal pipe Lo-pressure piping
● Expansion valve opening very wide
SA
NY
LA
● Frosting or condensation on Lo-pressure piping
Analysis
TI N
● Pressure at both Hi- and Lo-pressure ends very high
Cause
AM E
ZX215-1002174
4-158
Shop Manual - June 2013
Remedy
● Check the installation of thermal piping ● If thermal piping is normal, check the expansion valve. Replace defective expansion valve if observed.
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
● Compressing error Symptom: No refrigeration
04
5
-76 -01
15
05
{cmHg kgf/cm2}
08 0
085
● Pressure at Lo-pressure side very high
● Compressor internal leakage
-76 35 - 01 MPa
35
AM E
Cause
30
Analysis
● Compressing fault; ● Leaking or damaged valve, loosened parts
ZX215-1002175
Remedy ● Repair or replace compressor
SA
NY
LA
TI N
Symptom
25
3
0
MPa
● Pressure at Hi-pressure side very low
5
25
A
07
{cmHg kgf/cm2} 8 0 8.5 -50 0
10
7
1
20
1
06
6
2
2
15
RI C
3
4
02
01
15
05
03
Shop Manual - June 2013
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.7.14 Compressor oil Oil shall be added into the A/C system for lubrication. Compressor oil is solved in the refrigerant and circulates in the system. When the air conditioning system is shut down, compressor oil will stay inside the components. If no compressor oil is added into the system when replacing components, inadequate lubrication will result. Add compressor oil according to the chart below: Replaced component See "CAUTION" below
40
Evaporator 40
ND8# (10P, 10PA, 10S series compressor)
Compressor oil grade
A
Condenser
RI C
Volume (ml)
Compressor
ND9#(TV series compressor)
AM E
CAUTION
● Add oil into a new compressor according to the required volume of the system. When the compressor is to be replaced, discharge the surplus oil in it. ● Over-filling of compressor oil will reduce the refrigerating capacity. Short of compressor oil in the system will cause compressor abnormality.
SA
NY
LA
TI N
● Protect pipe joints and O-rings from contamination when disassembling the compressor.
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Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.8 Engine Control
5
4
A
3
TI N
AM E
RI C
2
LA
1
Battery relay
2)
Battery
3)
Engine start switch
4)
Fuel control dial
6)
SA
5)
NY
1)
Start motor
Engine controller
7)
Fuel injection pump
8)
Throttle motor
9)
Shutdown device
6
9
7
8
Z ZX215-1002176
Outline ● Start and stop the engine only with the engine start switch (3). ● The controller (6) receives the signal from the fuel control dial (4) and transmits the drive signal to the throttle motor (8) to control the governor lever angle of fuel injection pump (7) and control the engine speed. ● When engine start switch (3) is turned to the OFF position, the shutdown device (9) pulls the flame-out arm on the injection pump to the “parking” position and cuts the engine fuel supply. Then, the engine stops.
Shop Manual - June 2013
4-161
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.8.1 System operation Engine startup
(Power) Fuel ctrl dial
Start motor
Lo
Hi
Lo
When it happens, the controller checks the signal voltage from the fuel control dial and sets the engine speed to the speed set by the fuel control dial.
s E
Governor motor
S L
Safety relay
s P
SW B E
B BR C Lock relay
Alternator
Drive signal
(Potentiometer singal)
Throttle On
Bat. relay
RI C
Shutdown device
P B E
M P
Start S/W
Starting relay
(Starting signal)
A
Hi
Pilot S/W
Shutdown relay
(Starting signal)
Engine
Throttle Off
● When the start switch is turned to the START position, the starting signal is transmitted to the start motor. Then, the start motor rotates to start the engine.
Controller
(Regulating signal
(Start switch ON signal)
AM E
ZX215-1002177
● The fuel control dial sends a signal voltage corresponding to the rotation angle to controller.
Engine Fuel ctrl dial
Hi
Lo
LA
Throttle On
P B E
M P
Start S/W
Starting relay SW B
S
(Starting signal) L Safety s relay P
E
B BR C Lock relay
Alternator
Drive signal
Shutdown device
s E
Governor motor
(Potentiometer singal)
The controller sends a driving signal to the throttle motor according to the signal voltage to control the fuel injection pump, and eventually controls the engine speed.
Lo
Throttle Off
TI N
Hi
(Power)
Start motor
Bat. relay
Pilot S/W
Shutdown relay
(Starting signal)
Engine speed control
Controller (Regulating signal (Start switch ON signal)
NY
ZX215-1002178
Engine shutdown
(Power) Fuel ctrl dial
Hi
Hi
Lo
s E
Governor motor
Lo
P B E Throttle On
Start S/W
Starting relay
Start motor
SW B
S
(Starting signal) L
Safety s relay P
Alternator
E
B BR C Lock relay
Bat. relay
Shutdown device
Pilot S/W
Shutdown relay
(Starting signal)
Engine
Throttle Off
SA
● When the start switch is turned to the OFF position, the shutdown device cuts off the fuel supply and stops the engine.
Controller (Regulating signal (Start switch ON signal)
ZX215-1002179
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.8.2 Components 4.8.2.1 Fuel control dial 140° 9×10°
1 Level 1
Level 10
RI C
2
A
25°
Left limit
3
AM E
4
TI N
5
6
LA b
SA
Yellow
a
b
Blue
5V
VR
c
NY
a
1)
Right limit
c
Red
0V
ZX215-1002180
Knob
4)
Ball
2)
Dial
5)
Potentiometer
3)
Spring
6)
Connector
Shop Manual - June 2013
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Function
Remark:
4.49 4.75 5（V） Voltage˄V˅ ZX215-1002181
LA NY SA 4-164
A
0.25 1.72
RI C
0
TI N
The left limit is 0%; and the right limit is 100%.
100
AM E
● When throttle voltage is beyond the area, the controller sends out alarm code and the engine runs at low idle. The area under the sloping line is the abnormality detection area.
（%）
Dial angle
● Turning of the fuel control dial changes the resistance of the sliding rheostat inside the dial and the voltage signal collected by the controller. The controller calculates the collected signals and drives the throttle motor via signal output and controls the volume of the injection pump so that the engine can run at an optimal speed.
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.8.2.2 Controller
RI C
A
Controller
AM E
A
TYPE
TI N
USE FOR NO
SA
NY
LA
Controller port layout
ZX215-1002182
........ ........ ........ ........
................... ................... ................... ...................
A2
Shop Manual - June 2013
A1
ZX215-1002183
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Input and output signals A1
4-166
Input Input Input Input
Input Input Input Input Input
Signal name
Input/ output
NY
Signal name
SA
Travel speed switching solenoid Front pump solenoid valve Rear pump solenoid valve Swing priority solenoid valve Bucket confluence solenoid valve Boom priority 1 Boom priority 2 Motor drive signal + Motor drive signal Power ground Power ground Power ground Power ground Power supply(24V constant) Power supply(24V constant) Power supply(24V constant) Power supply(24V constant) Shop Manual - June 2013
Input/ output Input Input Input Output
A
Rear pump pressure sensor Sensor power ground Sensor power ground Sensor power Monitor CAN Low Calibrator CAN High Calibrator CAN Low Coolant temp very high R. travel pressure sensor Swing pressure sensor Bucket CURL pressure sensor Boom RAISE pressure sensor Arm IN pressure sensor Front pump pressure sensor Sensor PWR ground Sensor PWR Sensor PWR State indicator Monitor CAN High Monitor CAN Low Calibrator CAN Low Calibrator CAN shield wire Calibrator CAN High
RI C
Input Input Input Input Input
Pin No. 53 54 55 56 60 61 62 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81
TI N
Power ground Power ground Power ground Power supply(24V constant) Power supply(24V constant) Fuel level sensor Throttle position signal Engine speed signal RS232 ground RS232 receive Enable Coolant temperature sensor signal Oil temperature sensor signal Backup pilot pressure signal Fuel dial signal Engine speed signal ground RS232 send CPU mode Enable Engine oil pressure switch L. travel pressure sensor Bucket DUMP pressure sensor Boom LOWER pressure sensor Arm OUT pressure sensor
A2 Pin No. 82 88 89 97 98 99 100 104 113 114 115 116 117 118 119 120 121
Input/ output
Signal name
LA
Pin No. 1 2 3 4 5 11 15 19 22 23 24 30 31 33 34 38 41 42 43 48 49 50 51 52
AM E
A1
Input Input Input Input Input Input Input Output Output
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.9 Electrical Control System 4.9.1 Control function
A
Engine-Pump composite control function
RI C
Pump control function
AM E
Valve control function
Dual travel speed control
Electronic control system
Engine oil under-pressure alarm
Auto-deceleration/acceleration control
Engine speed calibration function
Self-diagnosis function
SA
NY
LA
TI N
Engine preheating/overheating alarm
NOTE: For detailed information about self-diagnosis function, see "Troubleshooting"
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.9.2 Machine control system diagram Battery
Battery relay
Fuel control dial Fuse
Power ON signal
Power supply
Swing priority signal
RI C
Monitor panel
R. travel signal
Network signal
Working mode signal Travel spd select signal Auto-deceleration signal Signal monitor info
Fuel level signal Hydraulic oil temperature signal
Hydraulic oil temp sensor
2
L. travel signal
3
Boom UP signal
4
Boom DOWN signal
AM E
Signal monitor info
Fuel level sensor
1
A
Power supply
Preheating signal
Starting signal
Start switch
5
Arm IN signal
6
Arm OUT signal
7
Bucket CURL signal
8
Bucket DUMP signal Swing signal
TI N
Controller
Travel spd select signal
11 17
LA
Bucket confluence signal
9 10
R.Pump EX press. signal
NY
15
Relay
Motor drive signal
Engine speed
PPC lock signal
Engine speed sensor
Engine oil pressure Coolant temp sensor
Safety relay
Charging indicator
Throttle position feedback signal
16
Starting signal
SA
12
F. Pump EX press. signal 13 F. Pump control signal 14 R. Pump control signal
Motor
Potentiometer
Oil pressure switch Coolant temp sensor Alternator
Engine
Starting signal Starting motor
Heater relay
Elct. intake air heater
Preheating signal
ZX215-1002184
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
1
2
R. travel pressure sensor
3
L. travel pressure sensor
4
Boom UP pressure sensor
5
Boom DOWN pressure sensor
6
Arm IN pressure sensor
7
Arm OUT pressure sensor
8
Bucket CURL pressure sensor
9
Bucket DUMP pressure sensor
A AM E
Swing pressure sensor
11
TI N
17
PPC Basic pressure
13 12
PPC Lock solenoid valve
15 14 R. Pressure sensor
Bucket confluence solenoid valve
Swing priority solenoid valve
XBp2
Main valve
PsP
Servo
SA
F
Travel speed solenoid valve
Control valve ports
PnA2
NY
F. Pressure sensor
Proportional valve
Proportional valve
Servo
LA
16
F. Pump oil-feed device Work equipment actuator
RI C
10
PPC Valve
R
Travel motor
Main pump
Swing motor
R. Pump oil-feed device Work equipment actuator
Travel motor
ZX225-1102049
Remark: The diagram above illustrates the electrical control system. For hydraulic circuit diagram, see Hydraulic System section.
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.9.3 Engine and pump composite control function
Operator cab
PPC valve
Monitor
Travel
Travel
MAX Boom UP/DOWN Bucket DIG/DUMP
Arm IN/OUT Swing
MIN
MC Controller input
RI C
A
Fuel control dial
Option pressure sensor
Pressure sensor
H/S/L/B Auto-idle cancel
AM E
Alarm output
Pilot oil pressure
Travel speed swithing
Engine chamber
P1
P2
Pressure sensor
Engine Oil-feed adjustment
Pump Pump proportional pressure reduce solenoid valve
Throttle motor
CAN path
SA
NY
LA
KC controller
TI N
Main control valve
Potentiometer
Motor
R. Pump control angle F. Pump control angle
Calibrator SW
LED
Engine speed Actual throttle position feedback
MEMORYON
LED
H
S
L
Control motor
A/I DOWN
7
UP
RPW
LED
PWR resouce DC24V (Battery)
SW H
S
L
A/I
Fuel, coolant temp and others
ZX215-1002186
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Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Function
Engine torque T
● This function allows the operator to select a working mode according to the job to be performed and change engine power output. Four different working modes are available: H, S, L and B. To select a working mode, use the working mode selector switch on the machine monitor.
H S L
RI C
A
● The main controller controls the pump so that it can absorb all the torque at the output points of the engine depending on the pump absorption torque specified for each mode, rotation set by the fuel control dial, and actual engine speed.
AM E
Engine speed N
H mode ~1600
Power (KW)
60
1600~1800 1800~2250 84
Engine speed
~1600
Power (KW)
60
115
S L
LA
S mode
TI N
Engine speed
H
Engine powerKW
Specifications
ZX215-1002193
1600~2250
Engine speed N ZX215-1002194
84
SA
Power (KW)
~2250 60
Pump deliveryQ
Engine speed
NY
L mode
H S L
Pump output pressureP ZX215-1002195
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Control method of each working mode
A Engine speed N ZX215-1002190
LA
TI N
Engine powerKW
AM E
● If pump load increases and pump pressure rises, engine speed drops. In this case, engine speed will rise to near the matching point, allowing the pump controller to reduce pump discharge. On the contrary, if pump load decreases and pump pressure drops, pump controller will continue to increase pump discharge until engine speed reaches the matching point.
RI C
● The matching point of H mode: rated speed 114kW/2050rpm
Engine torque T
H mode
Engine speed N
Pump deliveryQ
SA
NY
ZX215-1002191
Pump output pressureP ZX215-1002192
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
S mode/B mode/L mode
Mode
S
L
B
Power output rate
90%
80%
70%
Engine torque T
Power output rate of at each working mode
H S L
A
● At this time, the controller keeps the pump oil-suction torque in line with the stabling motor curve, and controls engine speed through combined control of the engine and pump.
Engine powerKW
S L
Engine speed N ZX215-1002194
Pump deliveryQ
NY SA
ZX215-1002193
H
LA
TI N
AM E
RI C
Engine speed N
H S L
Pump output pressureP ZX215-1002195
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.9.4 Pump control function
Fuel injection Throttle motor pump
A
R
Servo
(Control signal)
Proportional valve
LA
TI N
(Control signal)
AM E
Servo
Proportional valve
(Engine speed signal)
RI C
Speed sensor
(Throttle position feedback signal)
Lo
(Motor drive signal)
Hi
Press.sensor
F
M P
Fuel control dial
Press.sensor
Main pump
Engine
Monitor
R. Travel signal
L. Travel signal
(CANbus) Boom UP signal
Boom DOWN signal
Arm IN signal
Arm OUT signal
Bucket DIG signal
Bucket DUMP signal
SA
Swing signal
NY
Controller
ZX215-1002196
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.9.4.1 Electrical positive flow control
Pump 1 delivery amount Boom RAISE PPC pressure
RI C
A
Pump 1 delivery amount Arm IN PPC pressure
AM E
Pump 1 delivery amount Arm OUT PPC pressure Pump 1 delivery amount
MAX
Corresponding delivery output
LA
Bucket DUMP PPC pressure Pump 1 delivery amount
NY
Swing PPC pressure
SA
Pump 1 delivery amount
TI N
Bucket CURL PPC pressure Pump 1 delivery amount
L. Travel PPC pressure ZX215-1002197
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Pump 2 delivery amount Boom RAISE PPC pressure
RI C
A
Pump 2 delivery amount Arm IN PPC pressure
AM E
Pump 2 delivery amount Arm OUT PPC pressure Pump 2 delivery amount
MAX
Corresponding delivery output
Pump 2 delivery amount
LA
Bucket DUMP PPC pressure
TI N
Bucket CURL PPC pressure
Pump 2 delivery amount
SA
NY
Boom LOWER PPC pressure Pump 2 delivery amount
R. Travel PPC pressure
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ZX215-1002198
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Function
RI C
SA
NY
LA
TI N
● When the work equipment is operating, the controller collects the signal of pilot pressure sensor, and determines the control discharge amount of pump 1 and pump 2 according to the pressure signal.
AM E
Operation
A
● Use the joystick pilot pressure signal directly as the hydraulic pump discharge control signal. Pilot pressure is applied on the valve stem and, on the other hand, is collected by the controller. The controller keeps the discharge amount of the hydraulic pump at the specified value of the corresponding pilot pressure according to the functional relation between the set hydraulic pump discharge amount and pilot pressure. During combined operation, the set discharge amount of each operation shall be added.
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.9.4.2 Constant power control Function
Operation
Q Flow
A PMax
P
Pressure
SA
NY
LA
TI N
● When the work equipment is working, the controller collects the throttle gear signal,, a constant current value is provided and pump power control is achieved.
4-178
P0
RI C
PMax
Pump P-Q curve
AM E
● Calculation of theoretical maximum discharge amount of the pump. The system applies constant power control. The two adjustor act together hydraulically, and keep two executing unit of the same specification and acting together in synchronization. The change of pump discharge is determined by the sum of operating pressure of the two hydraulic pumps P∑ . When is met, the sum of the power of the two hydraulic pumps remains constant below the power of the engine.
Shop Manual - June 2013
ZX215-1002199
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
ESS control Function
RI C
A
● Changing of the engine speed due to load change controls the pump power, and engine output can be used more efficiently. (This function can also prevent the engine from losing control when the machine is operating under harsh conditions (eg. high - altitude area).
The engine control panel controls the target operating speed of the engine.
LA
TI N
● The engine controller collects the actual speed signal from the ECM, and preforms a closed loop control with the target operating speed. Then, the controller involves the output of closed-loop control with the calculation of the solenoid valve control signal, and sends the final adjusting current signal to the pump proportional solenoid valve.
AM E
Operation
SA
NY
● The solenoid valve feeds pilot pressure oil to the pump adjustor according to the signal of the controller, and controls the pump discharge amount.
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.9.5 Valve control function
Swing priortity
Bucket Confluence
Main pump
Fuel injection Throttle motor pump
Press.sensor
Press.sensor
F
M P
Speed sensor
R
Servo
(Control signal)
TI N (Control signal)
LA
(Engine speed signal)
Monitor
Controller
R. Travel signal
L. Travel signal
(CANbus) Boom UP signal
Boom DOWN signal
Arm OUT signal
Bucket DIG signal
Bucket DUMP signal
Swing signal
SA
NY
Lo
Proportional valve
Proportional valve
Arm IN signal
Hi
(Motor drive signal)
Fuel control dial
(Throttle position feedback signal)
AM E
Servo
RI C
Engine
A
Main valve
Valve control function ● Bucket flow control ● Swing priority control
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ZX215-1002200
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.9.5.1 Bucket flow control Function Swash plate angle
● Control the pump swash plate angle according to the operation of bucket control lever.
A
Max
Operation
ZX215-1002201
Bucket confluence proportional valve current
750mA
300mA Bucket control lever PPC pressure ZX215-1002202
SA
NY
LA
TI N
● When the bucket control lever is operated, the controller collects the signal from the bucket DUMP pressure sensor and bucket CURL pressure sensor, and controls the bucket confluence proportional valve.
Bucket control lever PPC pressure
AM E
RI C
Min
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.9.5.2 Swing priority control Function
A
● Pressurized oil from pump 1 bypasses bucket 1 valve spool, and flows first to swing motor valve spool to activate swing first.
AM E
TI N
● When signals from pump 1 pressure sensor, arm pressure sensor and swing pressure sensor meet the following conditions, the controller activates the solenoid valve. The solenoid valve conducts pilot pressure oil to arm flow controller and limits the alternate circuit of arm 1 valve spool. Swing valve spool first ensures swing motor power, preventing the counter acting force when the arm is retracting from affecting the positioning of the upper swing structure.
RI C
Operation
LA
Operating condition
● Swing pressure sensor: signal output available
SA
NY
● Arm pressure sensor: signal output available
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.9.6 Duo travel speed control
A
Travel motor
Regulator
Throttle motor
M P
SA
Travel Speed solenoid valve
R
Servo
(Control signal)
TI N
LA
NY
Lo
Main pump
F
Servo
(Throttle position feedback signal)
Hi
(Motor drive signal)
Fuel control dial
AM E
Engine Injection pump
(Control signal)
R. Travel pressure sensor
L. Travel pressure sensor
Main valve
RI C
Regulator
Monitor
Controller
(CANbus) ZX215-1002203
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Function ● Control travel mode. Operating condition ● When Hi speed travel mode on the monitor is enabled.
A
Operation
AM E
TI N
● When the controller receives the signal from the travel pressure sensor under the conditions below, it activates the solenoid valve. Then, the solenoid valve conducts pilot pressure oil to the swash plate angle control valve of the travel motor, and reduces the swash plate angle to increase travel speed.
RI C
● When the travel mode is set at LO speed, the swash plate angle of the travel motor is the largest, and travel speed is low.
Remark:
SA
NY
LA
When one side of the tracks is lifted off the ground by the work equipment and rotating, pressure at one side of the pump increases, which makes the lifted track rotate very fast. When the machine is traveling under Hi speed mode, even if work equipment is being operated (work equipment pressure sensor is switched ON), travel mode remains in Hi travel mode.
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.9.7 Engine preheating/overheating alarm
Start switch
Heat Main valve
Main pump F
Engine Throttle motor
LA
Monitor
(Control signal)
Servo
Controller
NY
(CANbus)
Servo
(Control signal)
Lo
TI N
Hi
(Motor drive signal)
Fuel control dial
(Throttle position feedback signal)
M P
R
AM E
Coolant tempe sensor
RI C
A
Preheat relay
Preheat s/w
SA
ZX215-1002204
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.9.7.1 Engine preheating Function ● Preheating control
Operating condition
RI C
TI N
● Power ON. Start key set at the HEAT position.
AM E
● This function shall be used in combination with the preheating switch located on the right armrest. Turn the engine start key counterclockwise to the HEAT position and hold on, the engine will start preheating. When released, the key will return to the OFF position automatically and preheating stops.
A
Operation
SA
NY
LA
● Preheating switch: ON
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.9.7.2 Engine overheating alarm Function ● When engine coolant temperature becomes excessively high (above 110°C) during operation, overheating alarm will be displayed on the monitor screen.
A
Operation
● Power ON.
TI N
● Coolant temperature above 110°C.
AM E
Operating condition
RI C
● The controller collects signal from the coolant temperature sensor. When coolant temperature rises too high, alarming information will be generated and transmitted to the machine monitor.
LA
4.9.8 Engine oil under–pressure alarm Function
SA
NY
● The engine controller collects signal from the engine oil pressure sensor. When engine speed exceeds 600 rpm, if oil pressure is too low, alarming information will be generated and transmitted to the machine monitor. The alarm indicator lights up when the monitor receives the signal.
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.9.9 Auto deceleration/acceleration control
Right joystick Boom
Bucket
OUT IN
UP DOWN
Engine
AM E
(Potentiometer signal)
Travel lever
A R.Travel
Reverse Forward
(Motor drive signal)
Arm
DUMP CURL
L.Travel
Reverse Forward
(Throttle signal) Monitor
L R
Fuel control dial
Left joystick
RI C
Swing
Engine throttle controller
TI N
Controller
SA
NY
LA
(CANbus)
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Control lever signal
ZX215-1002205
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Function ● If all the control levers are neutralized, engine speed will drop to the medium level automatically to reduce fuel consumption and noise.
A
● If any of the levers is operated, the engine speed rises to the set level instantly.
Speed (rpm)
Set rpm
Drop 100rpm
AM E
TI N
● About 3 second after all control levers are neutralized, engine speed will drop to the first deceleration level about 100 rpm lower than the set speed. After another 3 seconds engine speed enters low speed (1400 rpm) to reduce the loss of the hydraulic system and engine wear, and reduce fuel consumption and noise. When the control lever is operated again, the engine speed rises instantly to the previous level.
RI C
Operation
3s
Operated
Deceleration (1350rpm)
less than 2 S
Unoperated
Less than 1 S Time (s) Operated
Control lever
ZX215-1002206
SA
NY
LA
● If any control lever is operated while the engine speed is kept at decelerated level, engine speed will rise instantly to the level set by the fuel control dial.
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.9.10 Engine speed calibration function
Bucket confluence
Swing pripority
Pressure sensor
Engine
F
DOWN
UP
RPW
LED SW H
4-190
S
L
A/I
AM E (Control signaL)
TI N R. Travel signal
A/I
L. Travel signal
L
(CANbus) Boom UP signal
S
Boom DOWN signal
H
Swing signal
LED
Controller
Arm IN signal
LED
MEMORYON
7
(Control signaL)
(Engine speed signaL)
Calibtator
SW
Servo
Monitor
Arm OUT signal
SA
NY
Lo
Servo
LA
Hi
Bucket DIG signal
(Motor drive signaL)
Fuel control dial
Speed sensor
Bucket DUMP signal
(Throttle position feedback signaL)
M P
R
RI C
Throttle motor
Injection pump
Pressure sensor
Main pump
A
Main valve
Shop Manual - June 2013
ZX215-1002207
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Function ● Set the maximum engine speed under each working mode. This set speed is the standard to control engine speed.
Operation
RI C
A
● Calibrating procedure for positive flow excavators.
2) H, S, L maximum speed calibration, and A/ I speed calibration. 3) Turn the dial on the calibrator counterclockwise to the end 4) Power OFF
AM E
1) Selection of fixing point of throttle motor soft shaft
TI N
5) Set the calibrator to "Monitor mode", power on and check the result. Remark:
LA
Memory SW up: Calibration mode; Memory SW down: Monitor mode
SA
NY
For more information, see “Engine Speed Test and Calibrate” on page 6-3.
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.9.11 Electrical Components 4.9.11.1 Pump pressure sensor
Signal name
RI C
No.
A
Connection diagram
Terminal C Terminal B
A
PWR +5V
B
Output
Operation
ZX305-1002066
(V)
SA
NY
LA
● The relationship between the pressure applied on the sensor (P) and output voltage (E) is shown in the right diagram.
Sensor output voltage (E)
TI N
Terminal A
AM E
C
(MPa)
Oil pressure (P)
ZX215-1002209
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.9.11.2 Pilot pressure sensor
Connection diagram
PWR +5V
RI C
A
Signal name
A
No.
B
Terminal C Terminal B
Output
Terminal A
Operation
AM E
C
Sensor output voltage (E)
(V)
(MPa)
SA
NY
LA
TI N
● The relationship between the pressure applied on the sensor (P) and output voltage (E) is shown in the right diagram.
ZX305-1002066
Oil pressure (P)
ZX215-1002210
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
2
RI C
A
4.9.11.3 Engine speed sensor
1
Function
TI N
● The engine revolution sensor is installed to the ring gear of the engine flywheel. It electrically calculates the number of the gear teeth which pass in front of it and transmits the result to the engine controller.
AM E
ZX215-1002211
Operation
Standard value (@25°C)
LA
● Measure the resistance between terminal 1 and terminal 2 when it is in service. 2.3±0.2 kΩ
NY
● If the measured value exceeds the standard value, replace the sensor.
SA
CAUTION
● If the engine speed sensor is not tightened to the specified torque, the sensor may send out no signals. Tighten the engine speed sensor to the specified torque.
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SY195/205/215/225C9 Crawler Hydraulic Excavator
4.9.11.4 Coolant temperature sensor 2
1)
Sensor
2)
Connector
ZX215-1002212
AM E
RI C
A
1
Function
LA
TI N
● The output resistance of the engine coolant temperature sensor changes with the coolant temperature. The controller collects and processes coolant temperature signals and works out the coolant temperature.
80Ω (Ref.)
60°C
56.3Ω
80°C
29.5±10Ω
100°C
16.5Ω
106°C
14.3±0.5Ω
120°C
10Ω(Ref.)
SA
Standard value
50°C
NY
Specifications
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.9.11.5 Fuel level sensor
2
3
4
Float
3)
2)
Lever
4)
Casing
Coupler
SA
NY
LA
TI N
1)
AM E
RI C
A
1
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ZX215-1002246
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.9.11.6 Oil pressure switch
2
3
A
1
RI C
Load
O-ring
2)
Sensor
3)
Connector
ZX215-1002214
TI N
1)
AM E
Pressure
Function
LA
● The oil pressure switch is installed on the outlet circuit of the oil filter. It detects oil pressure and transmits warning signals to the controller.
NY
Specifications
● Type of contact: Normally closed type
SA
● Operating pressure: 1.9kg
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.10 Monitoring System
CAN signal
Monitor
AM E
RI C
A
Controller
Power
TI N
Sensor
LA
Battery
SA
NY
● The state of the machine is monitored by the sensors mounted on the machine components. The controller processes the signals and transmits the signals to the monitor display, informing the operator of the machine condition. ● Information on the monitor display includes primarily:
4-198
W13053001
1. Alert information when a machine fault is detected. 2. Operating condition (coolant temperature, fuel level, etc. ) ● The machine control system can be operated using the switches and keys on the monitor panel.
Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.10.1 Machine monitor
$
F1
F2
F3
Esc
F4
F5
TI N
Enter
AM E
RI C
A
%
Outline
LA
● The monitor displays various kinds of items and is used by the operator to select a working mode.
WX215-1204002H
● When the monitor is turned on, blinking strips may appear on the LCD screen. This is normal.
NY
● The monitor has a CPU which processes, displays, and outputs information.
SA
● The monitor has an LCD (Liquid Crystal Display) screen. NOTE:
● The LCD may have black spots (which do not light up) or bright spots (which stay on). Products having 10 or less black or bright spots conform to the product specification; such condition is quite normal. ● Continuous operation of the monitor may cause the LCD to display bright blue spots on a black background; it is quite normal.
Input and output signals No.
Signal name
Input/output
1
Digital input A
Input
3
CAN high
4
CAN low
7
Digital input B
8
Trigger power source (24V)
9
Power source (24V)
10
Grounding
11
Digital input C
12
Grounding
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Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4.10.2 Monitor functions The front side of the machine monitor is made up of three sections: A. Warning and signal indicators
A
$
%
B. Display screen
A
C. Key pad
AM E
RI C
B
Esc
F2
F3
F4
F5
Enter
XP13031506
LA
Warning and signal indicators
F1
TI N
C
NY
● When a machine fault occurs, the warning indicator lights up, reminding the user to check and address the fault.
SA
$
4-200
%
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Shop Manual - June 2013
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Screen display The LCD display is where monitor items are shown. This display is also the interface where most monitor operations are performed. Items on a normal operation display include: 1. Working mode indicator 2. Coolant temperature gage
A
Sany Hydraulic Excavator
6
1
4. Failure code 5. Total service hours
2
RI C
3. Fuel level gage
C
6. Function icons
10
H
AM E
7. System time (Hr: Min: Sec)
3
8. Date (YY:MM:DD)
E
F
4
9. GPS signal
5
10. Engine speed level (1 to 11)
KP
6
9 8 7
AUTO
n/min
TI N
6
(
LA
XP13032601
Key pad
1
F1 Esc
F2
F3
F4
F5
Enter
2
SA
NY
The key pad is composed of 5 function keys and six navigation keys.
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1. Function keys Functions of the five keys ( on the screen.
F1
,
F2
,
F3
,
F4
,
F5
) are indicated by the function icons above them
Function keys and icons Icon
Function
F1
AUTO
n/min
or
n/min
Home page
Select the next item; Go to the next page; Increase password value
Information Menu page Engine and Throttle Signal page, etc. Password Entry page
Save
System Time Calibration page, etc.
Lower monitor brightness
Brightness Adjustment page
A
Working mode selection
RI C
S , H L , B
Operation interface
AM E
Function key
Switch between Auto idle and Non Home page auto idle Move the cursor to the right
Password Entry page
F2
Increase monitor brightness
Brightness Adjustment page
Switch between High and Low travel speed
Home page
TI N
Information Menu page, etc.
LA
or
Enter a selected entry
Password Entry page
Confirm the validity of a password and, if it’s correct, enter the desired page. Save monitor brightness Go to “Fault Information” page Enter/Confirm
Password Entry page
SA
NY
F3
Password validation
F4
F5
Brightness Adjustment page Home page Same as Enter
Go to Brightness Adjustment page Password Entry page Go to System Setup page
Information Menu page
Go to Information Menu
Home page
Return to Home page, Information Password Entry page, etc. Menu or System Setup page Machine Configuration Calibration Save page Go to System Unlock page
Lockout Information page
NOTE: When no icon is displayed above a function key, this key is disabled.
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2. Navigation keys Navigation keys
Function
Enter
Enter/Confirm
ESC
Return
RI C
A
Select the item above (returns to the bottom item after the top item); or increase the value where the cursor blinks. Select the item below (returns to the top item after the bottom item); or decrease the value where the cursor blinks. Move the cursor to the left (returns to the right end digit after the left end digit).
AM E
Move the cursor to the right (returns to the left end digit after the right end digit).
4.10.3 Monitor operation 1. Home page
Operation
LA
TI N
The Home page is the normal operation display of the monitor. Items on this page include: truck load counter, working mode, speed level, coolant temperature, fuel level, service hours, clock, fault code, etc..
Working mode selection (1) F1
switch between S, H. L and B
6
NY
● Press mode.
Sany Hydraulic Excavator
SA
NOTE: S mode is the default working mode.
C
H
E
F
Auto-idle and Non auto-idle mode (2) ● Press F2 to switch between auto-idle and Non auto-idle mode. Auto-idle mode is indicated by
AUTO
n/min
.
Non auto-idle mode is indicated by
KP
6 n/min
(
AUTO
n/min
. XP13032602
NOTE: Auto-idle mode is the default mode.
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When neither of the joysticks are operated for 5 seconds, the engine enters the idling state automatically in order to save fuel and reduce noise. High and low travel speed (3)
.
Low travel speed is indicated by
.
RI C
High travel speed is indicated by
A
● Press F3 to switch between high and low travel speed.
NOTE: Default travel speed is Low.
● Press F4 to go to “Fault Information” when a fault occurs.
TI N
NOTE: When the ECU detects an error in the machine, a fault code will appear on the monitor display. The tick icon on the bottom will turn red.
AM E
Fault Information (4)
Information Menu (5)
SA
NY
LA
● Press F5 to go to the Password Entry page before accessing the “Information Menu” page.
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SY195/205/215/225C9 Crawler Hydraulic Excavator
2. Information Menu password entry A 5-digit password is required to access the “Information Menu”. You can ask your local dealer to obtain this password. Operation
A
1. Press F1 to change the number where the cursor blinks in an ascending order. You can also use or to increase or decrease the number.
RI C
Information Menu
2. Press F2 to move the cursor to the right. You can also use or to move the cursor to the left or to the right.
or
ESC
XP13031501
to return to the Home
LA
4. Press page.
F5
TI N
3. When all the five digits of the password have been entered, press F3 or Enter . If the password is correct, the display moves to the “Information Menu” page; if not, please try again.
＊ ＊ ＊ ＊ ＊
AM E
NOTE: The cursor moves back to the left end side after the right end side.
Please enter the password
SA
NY
5. Press F4 on this page to go to Brightness Adjustment page.
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3. Information Menu The information menu is a list of system functions. On this page, you can select and access any of the items on the list.
Information Menu
Operation Running parameter
● Press F1 to select the item below the highlighted one. The highlighter returns to the top after the bottom item. You can also use and to move the highlighter up and down.
● Press page.
or
Enter
System time setup GPS monitoring
to access the selected en-
Engine, pump and valve parameters
F5
or
ESC
to return to the Home
TI N
● Press F4 on this page to go to the Password Entry page before accessing the System Setup page.
LA
NOTE: Once an entry on the list is highlighted, an introductory hint will appear on the bottom of the display giving a short description of the selected entry. These hints include: ● Running parameters of the engine, main pup and main valve
NY
● Fault code and description
● Throttle installation assistance
SA
● System language selection ● System time setup ● GPS monitoring information
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A
System language
RI C
F2
Throttle installation
AM E
● Press try.
Fault information
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XP1251203007
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
4. Engine & Throttle Signal Select “Running Parameter” on the Information Menu page and press F2 or Enter , and the display moves to Engine & Throttle Signal page. This page is a real-time display of the running parameter of the engine and throttle.
Engine & Throttle Signal Coolant temp °C: Fuel level %:
Oil press kPa:
Operation
A
Throttle gear: F1
to go to “Pilot Pressure Signal”
Eng speed rpm:
RI C
● Press page.
Gear position V:
ESC
to return to the “Information
Throt position V:
AM E
● Press F5 or Menu”.
TI N
5. Pilot Pressure Signal
XP1251203008
LA
This page is a real-time display of the pilot pressure signal of the hydraulic system. Operation
NY
● Press F1 to go to “Main Pump and Main Valve Signal” page. ESC
to return to the “Information
Boom UP kg: Boom DOWN kg: Arm IN kg: Arm OUT kg: Bucket DIG kg: Bucket DUMP kg:
SA
● Press F5 or Menu”.
Pilot Pressure Signal
Swing kg: Travel L kg: Travel R kg:
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6. Main Pump & Main Valve Signal This page is a real-time display of the main pump and main valve signals of the hydraulic system.
Main Pump & Main Valve Signal
Operation
Pump1 press kg
● Press F1 to go to “Engine & Throttle Signal” page.
Prop valve2 current mA
to return to the “Information
A
ESC
Bucket confluence valve ż
RI C
● Press F5 or Menu”.
Pump2 press kg Prop valve1 current mA
Swing priority valve ż Boom priority valve ż
AM E
Hi/Lo speed switch ż
TI N
7. Fault Information
LA
Select “Fault Information” on the Information Menu page and press F2 or Enter , and the display moves to Fault Information page. This page lists important machine fault information. Operation
XP2051203010
Fault Information Current fault code:XXX XXX: XXX: XXX: XXX: XXX: XXX:
to go to the next page. ESC
XXX: XXX:
to return to the “Information
XXX: XXX: XXX: XXX:
SA
● Press F5 or Menu”.
XXX:
NY
● Press
F1
XXX: XXX: XXX: XXX:
XP13041501
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SY195/205/215/225C9 Crawler Hydraulic Excavator
8. Throttle Installation Select “Throttle Installation” on the Information Menu page and press F2 or Enter , and the display moves to Throttle Installation page. This page displays throttle installation assistance function.
Throttle Installation
Current gear N
Operation
A
Eng speed rpm 1200 ?
● Press F2 to switch between auto-idle and full speed.
● Press Menu”.
RI C
to select high or low travel
● For machines equipped with SYFCS controllers, press F4 to switch between rpm (blue) and rpm (red). F5
Throttle position V
or
ESC
to return to the “Information
AM E
● Press speed.
F3
Gear position V
rpm
AUTO
n/min
XP2051203013
9. System Language
LA
TI N
NOTE: For machines equipped with SYFCS controllers, when engine speed calibration is not successful, a question mark will appear.
● Press
F2
to select 中文.
● Press
F3
to select English.
● You can also use or tem language on the list. ● Press F5 or Menu”.
ESC
System Language
Ё᭛㋏㒳 English Systems
SA
Operation
NY
Select “System Language” on the Information Menu page and press F2 or Enter , and the display moves to this page.
to select a sys-
to return to the “Information
Ё᭛
(QJ
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10. System Time Setup Select “System Time Setup” on the Information Menu page and press F2 or Enter , and the display moves to this page. You can set system time on this page.
System Time Setup
Current time and time zone: 1234·12·12 12:12:12 W
Operation
F1
or
● Press F5 or Menu”.
to move the cursor. Enter
to save adjusted time.
ESC
to return to the “Information
Use > Ĺ @ > Ļ @ > ĸ @ > ĺ @ t o adj ust syst em t i m e
XP2051203015
TI N
NOTE: When F1 or Enter is pressed, the screen displays “Setup Finished” on the bottom. If system time has been adjusted, it cannot be adjusted again until the system is re-energized.
RI C
● Press
and
Setup time and time zone: 1234·12·12 12:12:12 W
AM E
● Use
A
● Use and to change the number where the cursor blinks.
11. GPS Monitoring
Operation
ESC
to return to the “Information
SA
● Press F5 or Menu”.
NY
LA
Select “GPS Monitoring” on the Information Menu and press F2 or Enter to view this page.
Remark:
● Longitude: “E” stands for “East”, while “W” for “West”.
GPS Monitoring Longitude ° ˖ Latitude °˖ Elevation m: Speed Km/h: Satellite No.: Comm index˖ S/N ratio 1˖ S/N ratio 2˖ S/N ratio 3˖ S/N ratio 4˖
G% G% G% G%
● Latitude: “N” stands for “North”, while “S” for “South”. ● Altitude: “P” means “Above Sea Level”, while “N” means “Below Sea Level”.
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XP130426011
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
● The blue-white bars show signal-to-Noise ratio ranges from 0 to 99. ● When the altitude is nonzero and the longitude and latitude is zero, it means that the system is receiving GPS data, yet still in the process of precise positioning.
A
● GPS is normal when the signal indicator shows 1023, otherwise it is abnormal when the signal indicator shows 615.
AM E
● When the signal indication changes to 0 from 15, it is either because the GPS service is not available, or the SIM card charge is overdue, or the GPS network is abnormal.
RI C
● When the signal indication changes to 0 from 7, a connection failure occurs either in the SIM card or in the antenna.
LA
12. Brightness Adjustment
TI N
● When the signal indication changes to 0 from 31, it is because the monitoring center suspends.
Operation
NY
Press F4 on the Information Menu Password Entry page to go to Bright Adjustment page. This page is used to adjust monitor screen brightness.
Brightness Adjustment Brightness: 20%
SA
● Press F1 to decrease brightness level. The progress bar moves to the left side. Minimum brightness is 10%. ● Press F2 to increase brightness level. The progress bar moves to the right side. Maximum brightness is 100%. ● Press ● Press Menu”.
F3
F5
Tips: Use F3 to save brightness value.
to save brightness adjustment. to return to the “Information
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13. System Setup password entry Press F4 on the Information Menu page to enter the Password Entry page before accessing the System Setup page.
System Setup
Operation Please enter the password
A
1. For password entry method, see Information Menu Password Entry page.
F5
or
ESC
to return to the Home
AM E
3. Press page.
RI C
2. When all the five digits of the password have been entered, press F3 or Enter . If the password is correct, the display moves to the “System Setup” page; if not, please try again.
XP130426012
TI N
NOTE: Contact your local dealer to obtain this password. 14. System Setup
LA
This page is used to set up machine configuration. Operation
SA
NY
● Press F1 to select the item below the highlighted one. The highlighter returns to the top after the bottom item. You can also use and to move the highlighter up and down. ● Press try.
● Press page.
F2
F5
or
Enter
or
System Setup
Machine configuration Service hour setup Machine configuration setup Hydraulic oil temperature
to access the selected en-
ESC
to return to the Home
XP2051203016
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SY195/205/215/225C9 Crawler Hydraulic Excavator
15. Machine Configuration password entry Select Machine Configuration on the System Setup list and press F2 or Enter , and the display moves to the Password entry page before accessing the Machine Configuration page.
System Setup
Please enter the password
A
Operation
ESC
to return to the “System
16. Machine Configuration
XP13060801
TI N
3. Press F5 or Setup” page.
AM E
2. When all the five digits of the password have been entered, press F3 or Enter . If the password is correct, the display moves to the “Machine Configuration” page; if not, please try again.
RI C
1. For password entry method, see Information Menu Password Entry page.
LA
You can view machine configuration information on this page. Operation ESC
to return to the “System
NY
● Press F5 or Setup” page.
Machine Configuraiton
Machine model： Machine No.:
SA
Engine model: Hydr system model: Controller model:
XP13041502
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17. Service Hour Setup password entry Select “Service Hour Setup” on the System Setup list and press F2 or Enter , and the display moves to the Password entry page before accessing the Service Hour Setup page.
System Setup
Operation
Please enter the password
ESC
to return to the “System
RI C XP13060802
TI N
3. Press F5 or Setup” page.
AM E
2. When all the five digits of the password have been entered, press F3 or Enter . If the password is correct, the display moves to the “Service Hour Setup” page; if not, please try again.
A
1. For password entry method, see Information Menu Password Entry page.
18. Service Hour Setup
LA
This page is used to set up machine service hours. Operation
● Use
F1
or
to move the cursor.
Enter
to save adjusted time.
SA
● Press
and
NY
● Use and to change the number where the cursor blinks.
● Press F5 or Setup” page.
ESC
Current service hour 100 h 50 m Setup service hour 100 h 50 m
to return to the “System Use >Ĺ@>Ļ@>ĸ@>ĺ@ to adjust service hour
NOTE: When F1 or ENTER is pressed, the screen displays “Setup Finished” on the bottom. If system time has been adjusted, it cannot be adjusted again until the system is reenergized.
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Service Hour Setup
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XP2051203021
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
19. Machine Configuration Setup password entry Select “Machine Configuration Setup” on the System Setup list and press F2 or Enter , and the display moves to this Password entry page.
㋏㒳䆒㕂
䇋䕧ܹᴎ఼䜡㕂䆒ᅮᆚⷕ˖
A
Operation
ESC
to return to the “System
XP13060803
SA
NY
LA
TI N
3. Press F5 or Setup” page.
AM E
2. When all the five digits of the password have been entered, press F3 or Enter . If the password is correct, the display moves to the “Machine Configuration Setup” page; if not, please try again.
RI C
1. For password entry method, see Information Menu Password Entry page.
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20. Machine Configuration Setup This page is used to set up machine configuration after installation of the monitor. Machine Config Setup
Operation F1
to change machine model.
● Press
F2
to change engine model.
F4
to change hydraulic system
Hydraulic model:
RI C
● Press
F3
Engine model:
Control model:
to change controller model.
● Press F5 to save machine configuration. The screen displays “Setup finished. Please re-energize the system.” ● Press Enter to move the cursor between different parts in the machine number.
Machine No.:
Use>Ĺ@>Ļ@>ĸ@>ĺ@ to set up machine number
AM E
● Press model.
Machine model:
TI N
● Use and to increase and decrease the selected machine number by 100 each time.
LA
● Use and to increase and decrease the selected machine number. One quick pressing increase or decrease the number by 1. Long pressing increase or decrease the number in a quicker pace.
to return to the “System Setup”
NY
ESC
SA
● Press page.
4-216
A
● Press
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Mach Eng
Hydr
Cont XP13041503
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
Remark: The machine serial number is composed of 4 parts: 1) Production year, 2) Product code, 3) Tonnage code, 4) Alteration code, 5) Serial number, and 6) Tail number “8”.
A
1) Press Enter to move the cursor to different part (Production year, Product code and Serial number) in the machine number.
AM E
3) When the cursor moves to Tonnage code, press and to increase or decrease tonnage code by 1 each time; or press and to increase or decrease tonnage code by 100 each time.
RI C
2) When the cursor moves to Production year and Alteration code, press and to increase or decrease Production year and Alteration code by 1 each time.
LA
TI N
4) When the cursor moves to Serial number, press and to increase or decrease this number by 1 each time. Long pressing to change the number in a quick pace. Press and to increase or decrease this number by 100 each time.
SA
NY
5) The machine number has 4 adjustable digits. Use and to switch between the four digits, and use and to change the value on a digit. The value of the first digit from the left could be any numbers from 0 to 9 and any letters from A to Z; the value of the rest three digits could only be any number from 0 to 9. When the number exceed 9999, capital letter from A to Z will have to be used. A, B, C, D, E ... means respectively 10000, 11000, 12000, 13000, 14000, 15000 .... For example: 10000 will be written as A000; 11020 as B020, 12999 as C999.
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21. Hydraulic Oil Temperature Select “Hydraulic Oil Temperature” on the System Setup list and press F2 or Enter , and the display moves to this page.
Hydraulic Oil Temp
Operation
Hydraulic Oil Temp:
to return to the “System
A
ESC
SA
NY
LA
TI N
AM E
RI C
● Press F5 or Setup” page.
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XP2051203028
Structure and Function
SY195/205/215/225C9 Crawler Hydraulic Excavator
22. Lockout Information (Level 1) This display indicates that the machine has entered lockout state (level 1). Lockout Information
Operation ● Press
F5
to enter “System Unlock” page.
Macine model: Machine No.:
RI C
Current time:
A
Machine state: Lockout (1)
NOTE: Contact your local dealer to unlock the machine when the system is locked.
System locked
TI N
AM E
Contact manufacturer to unlock system
XP13041504
30. Lockout Information (Level 2)
Operation ● Press
F5
LA
This display indicates that the machine has entered lockout state (level 2).
to enter “System Unlock” page.
Lockout Information
Macine model:
NY
Machine No.:
SA
NOTE: Contact your local dealer to unlock the machine when the system is locked.
Machine state: Lockout (2) Current time:
System locked Contact manufacturer to unlock system
XP13041505
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BSLAN AYNL AT K IN PAA ME G RI E CA
Structure and Function
4-220
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RI C
Standard Values
A
Standard Values
SY195/205/215/225C9 Crawler Hydraulic Excavator
5 Standard Values
SA
NY
LA
TI N
AM E
5.1 Standard Values of Engine - related Parts............................................................... 5-3 5.2 Standard Values of Chassis-related Parts ............................................................... 5-4
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5-1
Standard Values
SA
NY
LA
TI N
AM E
RI C
A
SY195/205/215/225C9 Crawler Hydraulic Excavator
5-2
WARNING
Read and understand all safety precautions and instructions in this manual before reading any other manuals provided with this machine and before operating or servicing the machine. Also read the safety information on machine decals before performing any operations. Failure to do so can cause machine damage, personal injury or death.
Shop Manual - June 2013
Standard Values
SY195/205/215/225C9 Crawler Hydraulic Excavator
5 STANDARD VALUES 5.1 Standard Values of Engine - related Parts Std. value for new machine
Permissible value
High Idling
rpm
2,060 ± 70
2,060 ± 70
Engine Speed Low Idling
rpm
1,050 ± 50
1,050 ± 50
rpm
2,000
kPa {mmH2O}
Min. 133 {Min. 1,000}
Min. 133 {Min. 1,000}
Max.25
35
At High Idling
Bosch Index
—
—
Valve Clearance
Intake Valve
mm
0.25
0.152 ~ 0.381
Exhaust Valve
mm
0.51
0.381 ~0.762
Compression Pressure
● Oil Temp: 40~60°C
Mpa
Min. 2.41
1.69
{kg/cm²}
{Min. 24.6}
{17.2}
Blow-by Pres- ● Coolant Temp: Working Range kPa sure {mmH2O} ● Arm-In Overflow: Max. rpm
Max. 0.98 {Max. 100}
1.96 {200}
High Idling
MPa {kg/cm²}
Min. 0.29 {Min. 3.0}
0.25 {2.5}
Low Idling
MPa {kg/cm²}
Min. 0.10 {Min. 1.0}
0.07 {0.7}
°C
80 ~ 110
120
mm
8.0
Min. 6, Max. 10
mm
5~8
5 ~8
Intake Pressure (Negative Pressure)
● Air Cleaner Outlet Location ● Arm-In Overflow+Max. rpm
TI N
At Sudden Acceleration
● Engine Speed 250 rpm
Oil Pressure
● Full Speed Range (In Oil Pan)
NY
Oil Temp.
LA
Exhaust Color
● Deflection when pressed with finger force of 58.8 N {6 kg}
SA
Fan Belt Tension
● Between fan belt pulley and alternator belt pulley
● Between fan belt pulley and A/C Comprescompressor belt pulley sor Belt Ten● Deflection when pressed with sion finger force of 58.8 N {6 kg}
Shop Manual - June 2013
2,000
RI C
Rated Speed
AM E
Measurement condition
A
Unit
Item
5-3
Standard Values
SY195/205/215/225C9 Crawler Hydraulic Excavator
5.2 Standard Values of Chassis-related Parts Categ.
Item
Measurement condition
Unit
Std. value for new machine
Permissible value
2,030 ± 50
2,030 ± 50
● Arm-in relief condition ● Engine running at high idle
Speed when auto deceleration is oper- ● Auto idling switch on ated ● All control levers neutral
11.5 ± 0.5
11.5 ± 0.5
DOWN
mm
9.5 ± 0.5
9.5 ± 0.5
IN
mm
11.5 ± 0.5
11.5 ± 0.5
OUT
mm
9.5 ± 0.5
9.5 ± 0.5
DIG/DUMP
mm
9.5 ± 0.5
9.5 ± 0.5
mm
9.5 ± 0.5
9.5 ± 0.5
mm
9.5 ± 0.5
9.5 ± 0.5
mm
85 ± 10
85 ± 10
mm
85 ± 10
85 ± 10
mm ● Max. reading at stroke end (except mm lever play in NEUTRAL position) mm ● Engine stopped Work Equipmm ment ● Slightly push the
85 ± 10
85 ± 10
85 ± 10
85 ± 10
115 ± 12
115 ± 12
Max. 15
Max. 20
Max. 20
Max. 25
TI N
Spool Stroke
● Engine stopped
Swing control valve
Travel (L&R) Forward & Reverse
Travel control valve
Swing control lever
● Control lever grip at center
NY
Travel control lever
SA
Control Lever stroke
Bucket control lever
● Engine stopped
LA
Arm control lever
Play of control lever
control lever. Stop pushing when resistance is felt.
Stroke
● Max. reading at
stroke end.
5-4
1,400 ± 100
mm
Bucket control valve ● See Control valve.
Boom control lever
1,400 ± 50
UP
Boom control valve Arm control valve
rpm
A
● Heavy-load operating mode (H)
RI C
2 pumps at relief
● Hydraulic oil temperature: Within operational range rpm ● Engine running at high idle
AM E
Engine Speed
● Engine coolant temperature: Within operational range
Shop Manual - June 2013
mm
Standard Values
Boom control lever Arm control lever Bucket control lever Swing control lever Travel control lever Travel control pedal
Measurement condition
● Hydraulic oil temp: Within operational range ● Engine running at high idle
N {kgf}
● Control lever grip at center ● Pedal at tip ● Max. reading at stroke end
● Engine running at high idle ● Working mode: H
AM E
● Hydraulic oil temp: Within operational range Unloaded pressure
Unit
Std. value for new machine Max. 19.6 {Max. 2.0} Max. 19.6 {Max. 2.0} Max. 15.6 {Max. 1.6} Max. 15.6 {Max. 1.6} Max. 30.4 {Max. 3.1} Max. 93.1 {Max. 9.5}
Permissible value Max. 24.5 {Max. 2.5} Max. 24.5 {Max. 2.5} Max. 21.6 {Max. 2.2} Max. 21.6 {Max. 2.2} Max. 39.2 {Max. 4.0} Max. 107.8 {Max. 11}
0~1.0 {0~10}
0~2.0 {0~20}
34.3 ± 1.0 {350 ± 10} 34.8 ± 1.0 {355 ± 10}
33.3 ~ 35.3 {340 ~ 360} 33.3 ~ 36.8 {340 ~ 375}
34.8 ± 1.0 {355 ± 10}
33.3 ~ 36.8 {340 ~ 375}
25.5 ± 1.0 {261 ± 10}
24.5 ~ 27.5 {250 ~280}
33.4 ± 1.0 {342 ± 10}
32.4 ~ 34.4 {330 ~ 351}
3.9 ± 0.2 {40 ± 2}
3.7 ~ 4.1 {37 ~ 41}
A
Item
RI C
Categ. Operating Force of Control Lever/ Pedal
SY195/205/215/225C9 Crawler Hydraulic Excavator
● Hydraulic pump output pressure ● Hydraulic oil temp: Within operational range
Arm relief
● Operate corresponding control lever after engine runs at high idling speed.
TI N
Boom relief
● Hydraulic pump output pressure with all measurement circuits relieved MPa ● Hydraulic oil temp: Within operational {kg/cm²} range
NY
Swing relief
LA
● Working mode: H Bucket relief
Travel relief
SA
Hydraulic Pressure
● All control levers in neutral position
● Operate corresponding control lever after the engine runs at high idling speed. ● Working mode: H
● Hydraulic pump output pressure with all measurement circuits relieved ● Hydraulic oil temp: Within operational range
Control circuit ● Engine running at high idle source pres● Self pressure reducing valve output sure pressure with all control levers in NEUTRAL position
Shop Manual - June 2013
5-5
Standard Values
Categ.
SY195/205/215/225C9 Crawler Hydraulic Excavator
Item
Measurement condition
Unit
Std. value for Permisnew machine sible value
● Hydraulic oil temp: Within operational range Max. 100 (—)
Max. 130 (—)
3.1 ± 0.3
Max. 3.7
RI C
● Engine running at high idle
Swing brake angle
● Working mode: H
Deg. ● Swing circle misalignment amount when stopping mm after one turn
4.4 ± 0.4
Max. 5.5
27 ± 3.5
Max. 30
0
0
Max. 5
Max. 10
51.3 ± 5.1
46.2 - 60.4
28.0 ± 1.4
26.6 - 31.4
Time taken to start swing
● Working mode: H
A
● For measuring posture see Swing 1. ● Hydraulic oil temp: Within operational range 90° sec. ● Engine running at high idle
● For measuring posture see Swing 1.
AM E
● Time required for passing points 90°and 180° sec. 180° from starting point
● Engine running at high idle
Time taken to swing
● Working mode: H
● Time required for 5 turns after making initial 1 turn
sec.
TI N
Swing
● Hydraulic oil temp: Within operational range
● For measuring posture see Swing 1.
● Hydraulic oil temp: Within operational range ● Engine stopped
● Keeping the upper structure transverse on a grade of 15°. For more information see Swing 2. mm
LA
Hydraulic drift
● Notching a mating mark on inner and outer races of the swing circle
● Engine running at high idle ● Swing lockout switch: ON
SA
Motor leakage
NY
● Mating mark misalignment amount during 5 min. ● Hydraulic oil temp: Within operational range ml/ min
Travel
● Leakage amount for 1 minute during swing relief ● Hydraulic oil temp: Within operational range Lo
Travel speed (unloaded)
● Engine running at high idle ● Working mode: H ● Time required for track shoes to make 5 Hi turns after making one initial idle turn ● For more information on measuring posture see Travel 1.
5-6
Shop Manual - June 2013
sec.
Standard Values
Measurement Condition
● ● ● ● ● ●
Hydraulic oil temp: Within operational range Engine running at high idle Working mode: H Travel Speed: Low mm Hard level ground Amount of deviation (χ) while traveling 20m after initial 10m trial run For measuring posture see Travel 2/3. Hydraulic oil temp: Within operational range Engine stopped Park the machine on a grade of 12°, with the sprocket mm in the downhill direction Measure the sliding distance for 5 minutes For measuring posture see Travel 4.
27.2
mm
Max. 600
Max. 900
mm
Max. 20
Max. 27
mm
Max. 20
Max. 20
mm
Max. 45
Max. 45
TI N
AM E
13.6
Hydraulic oil temp: Within operational range Flat and level ground Bucket full of earth or with rated load (0.8m³: 1,440 kg) Boom horizontal, arm fully retracted and bucket cylinder fully extended Engine stopped Work equipment control lever in neutral position Measure total amount of falling for 15 min. by measuring the falling every 5 min. immediately after initial setting ● Bucket tip lower distance ● Boom cylinder: Cylinder retracting distance ● Arm cylinder: Cylinder extending distance ● Bucket cylinder: Cylinder retracting distance For measuring posture see Work Equipment 1.
NY
Bucket cylinder
11.5~15.5
0
LA
Leakage of travel motor Bucket tips
13 ± 2.5
0
● ● ● ●
SA
17.5~22.5
Max. 900
Hydraulic oil temp: Within operational range Engine running at high idle Traveling with the sprocket locked mm Oil leakage amount for one minute with traveling in relief condition
●
20 ± 2.5
Max. 800
● ● ● ●
● ● ●
Std. value for Permisnew machine sible value
RI C
Hydraulic oil temp: Within operational range Lo Engine running at high idle Working mode: H sec. Level ground Time required for traveling 10m after 10m trial run Hi For measuring posture see Swing 2.
● ●
Arm cylin- Boom der cylinder
Hydraulic drift
Work Equipment
Unit
● ● ● ● ● ●
● ● ● ●
Hydraulic drift
Travel
Deviation
(Actual run)
Item
Travel speed
Cat.
A
SY195/205/215/225C9 Crawler Hydraulic Excavator
Shop Manual - June 2013
5-7
Standard Values
Categ.
Item
SY195/205/215/225C9 Crawler Hydraulic Excavator
Measurement condition
Unit
Std. value for Permisnew machine sible value
● Hydraulic oil temp: Within operational range Boom
● Engine running at high idle ● Working mode: H ● Time required for the bucket to raise from the ground to its stroke end
UP
sec.
IN
sec.
● For measuring posture see Work Equipment 3.
TI N
● Hydraulic oil temp: Within operational range
AM E
● Working mode: H ● Time required from dumping stroke end to digging stroke end
Max. 4.8
A
● Engine running at high idle
RI C
● Hydraulic oil temp: Within operational range
Arm
Work Equipment Speed
Work Equipment
● For measuring posture see Work Equipment 2.
3.4 ± 0.4
2.8 ± 0.4
Max. 4.5
OUT
sec.
2.3± 0.3
Max. 3.5
DIG
sec.
2.3 ± 0.4
Max. 3.4
sec.
1.6 ± 0.3
Max. 2.3
● Working mode: H
● Time required from dumping stroke DUMP end to digging stroke end
LA
Bucket
● Engine running at high idle
SA
NY
● For measuring posture see Work Equipment 4.
5-8
Shop Manual - June 2013
Standard Values
SY195/205/215/225C9 Crawler Hydraulic Excavator
Item
Measurement condition
Unit
Max. 1.2
A
Max. 1.0
RI C
Hydraulic oil temp: Within operational range Engine running at low idle Working mode: H Time required from maneuvering the joystick to the moment that the bucket reaches the sec. ground and begins to push the machine upward, within 50mm off the ground ● For measuring posture see Work Equipment 5.
Std. value for Judgement new machine criteria
● ● ● ●
Hydraulic oil temp: Within operational range Engine running at low idle Working mode: H Average time required for operating the consec. trol lever back and forth till the arm starts to move ● For measuring posture see Work Equipment 6.
AM E
● ● ● ●
Hydraulic oil temp: Within operational range Engine running at low idle Working mode: H Average time required for operating the consec. trol lever back and forth till the arm starts to move ● For measuring posture see Work Equipment 7.
Max. 2.0
Max. 2.8
Max. 1.0
Max. 3.6
5
20
10
50
Max. 200
Max. 220
LA
TI N
● ● ● ●
NY
Central Swivel Cylinders Joint work equipment and travel
Amount of deviation in simultaneous operation of
Performance in Combined Operations
SA
Internal Leakage
Bucket
Arm
Time Delay
Work Equipment
Boom
Cat.
● Hydraulic oil temp: Within operational range ml/ ● Engine running at high idle ● Leakage amount for one minute with cylinder min or travel measured at relief condition
● ● ● ● ●
Hydraulic oil temp: Within operational range Engine running at high idle Working mode: H Travel Speed: Low mm Amount of deviation measured for 20 m after traveling about 10 m on a hard level ground ● For measuring posture see Travel 2.
Shop Manual - June 2013
5-9
Standard Values
SY195/205/215/225C9 Crawler Hydraulic Excavator
Machine postures for measuring (For all models) Travel 1: Travel speed (without load)
Travel 2: Travel speed (actual run), Travel deviation
TI N
Swing 1: Swing brake angle, time taken to start swing, time taken to swing
ZX215-1003005
AM E
ZX215-1003002
RI C
A
Control value: Spool stroke
NY
LA
45°
ZX215-1003003
ZX215-1003006
Travel 3: Travel deviation
SA
Swing 2: Hydraulic drift of swing
15°
x 10m ZX215-1003007
Sprocket ZX215-1003004
5-10
Shop Manual - June 2013
Standard Values
SY195/205/215/225C9 Crawler Hydraulic Excavator
Travel 4: Hydraulic drift of Travel
Work equipment 3: Arm speed
RI C
A
12°
ZX215-1003008
AM E
Work equipment 4: Bucket speed
LA
TI N
Work equipment 1: Hydraulic drift of work equipment
ZX215-1003011
ZX215-1003009
Work equipment 2: Boom speed
ZX215-1003012
SA
NY
Work equipment 5: Boom delay
ZX215-1003010
Shop Manual - June 2013
ZX215-1003013
5-11
Standard Values
SY195/205/215/225C9 Crawler Hydraulic Excavator
Work equipment 7: Bucket delay
RI C
A
Work equipment 6: Arm delay
ZX215-1003015
SA
NY
LA
TI N
AM E
ZX215-1003014
5-12
Shop Manual - June 2013
Standard Values
SA
BLNY ANLA TI KN PAAM E G RI E CA
SY195/205/215/225C9 Crawler Hydraulic Excavator
Shop Manual - June 2013
5-13
SY195/205/215/225C9 Crawler Hydraulic Excavator
BSLAN AYNL AT K IN PAA M GERI E CA
Standard Values
5-14
Shop Manual - June 2013
Testing and Adjusting
A
SY195/205/215/225C9 Crawler Hydraulic Excavator
RI C
Testing and Adjusting 6 Testing and Adjusting
SA
NY
LA
TI N
AM E
6.1 Engine Speed - Test and Calibrate .......................................................................... 6-3 6.1.1 Testing ........................................................................................................... 6-3 6.1.2 Adjusting ........................................................................................................ 6-3 6.2 Exhaust Gas Color - Test ......................................................................................... 6-6 6.3 Valve Clearance - Adjust.......................................................................................... 6-8 6.3.1 Testing............................................................................................................ 6-8 6.3.2 Adjusting ...................................................................................................... 6-10 6.4 Compression Pressure - Measure ..........................................................................6-11 6.5 Fuel Injection Timing - Test and Adjust .................................................................. 6-13 6.5.1 Testing.......................................................................................................... 6-13 6.5.2 Adjusting ...................................................................................................... 6-15 6.6 Engine Oil Pressure - Measure.............................................................................. 6-17 6.7 Engine Speed Sensor - Adjust ............................................................................... 6-19 6.8 A/C Compressor Belt Tension - Test and Adjust ................................................... 6-20 6.8.1 Testing ......................................................................................................... 6-20 6.8.2 Adjusting ...................................................................................................... 6-20 6.9 Swing Bearing Clearance - Measure ..................................................................... 6-22 6.10 Track Tension - Test and Adjust ........................................................................... 6-24 6.10.1 Testing........................................................................................................ 6-24 6.10.2 Adjusting .................................................................................................... 6-25 6.11 Hydraulic Pressure in Hydraulic Circuits - Test and Adjust .................................. 6-26 6.11.1 Measuring .................................................................................................. 6-26 6.11.2 Adjusting..................................................................................................... 6-28 6.12 Control Circuit Oil Pressure - Test and Adjust...................................................... 6-30 6.12.1 Testing........................................................................................................ 6-30 6.12.2 Adjusting .................................................................................................... 6-31 Shop Manual - June 2013
6-1
Testing and Adjusting
Solenoid Valve Output Pressure - Measure......................................................... 6-32 Pilot Valve Output Pressure - Measure................................................................ 6-34 Pilot Valves (Work Equipment and Swing) - Adjust ............................................. 6-36 Work Equipment Hydraulic Drift - Test ................................................................. 6-37 Residual Pressure in Hydraulic Circuit - Release ................................................ 6-40 Oil Leakage - Measure ........................................................................................ 6-41 Air in Each Component - Bleed............................................................................ 6-46
SA
NY
LA
TI N
AM E
RI C
A
6.13 6.14 6.15 6.16 6.17 6.18 6.19
SY195/205/215/225C9 Crawler Hydraulic Excavator
6-2
WARNING
Read and understand all safety precautions and instructions in this manual before reading any other manuals provided with this machine and before operating or servicing the machine. Also read the safety information on machine decals before performing any operations. Failure to do so can cause machine damage, personal injury or death.
Shop Manual - June 2013
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6 TESTING AND ADJUSTING 6.1 Engine Speed - Test and Calibrate Engine speed calibrator
1
Part Number
Part Name
B249900001206 Engine Speed Calibrator
A
ID
Testing Items: 1. Engine speed at low idle
AM E
Start the engine and keep the engine running until engine coolant temperature rises within the operational range. Key in the code on the monitor and check if the engine speed is normal in each throttle position.
RI C
6.1.1 Testing
TI N
2. Engine speed at fuel control dial position 11 (H and S modes)
LA
3. Engine speed at relief, with fuel control dial placed at position 11 (H and S modes) 4. Engine speed at auto idle
NY
6.1.2 Adjusting
SA
Adjust the fixing point of the flexible shaft of the throttle motor. 1. Connect the calibrator with the chassis harness.
ENG. Shaft bracket
2. Push the memory switch of the calibrator down to the OFF position. 3. Turn the start switch of the machine to the ON position.
Tighten Lock nut Loosen
Min. throttle
4. Start the engine. Check if engine speed is within 1100±50 rpm range. (Throttle voltage at speed level 1 is 1.3±0.03V)
Shop Manual - June 2013
Max. throttle
Flexible shaft
WX215-1304008
6-3
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
5. Tighten the fixing position of the flexible shaft when engine speed is lower than 1050 rpm; loosen the fixing position of the flexible shaft when engine speed is higher than 1150 rpm. 6. Shutdown the engine. Speed calibration steps:
RI C
2. Push the memory switch of the calibrator down to the OFF position. Turn the start switch of the machine to the ON position.
A
1. Connect the calibrator with the chassis harness. Memory s/w
3. Start the engine. Engine speed “XXXX” will be displayed on the screen display of the calibrator. Press the H button and hold it, the screen will display “E. XXXX”.
H
H
5. Shut off the engine.
H button
LA
NOTE:
SA
NY
In order to make sure speed calibration is successful, deactivate auto-idle mode after the calibration process and check the idling speed at each speed level. If excessive variation is found between the real speed and the target speed, try automatic speed calibration once again.
6-4
S
S
L
L
A/I DOWN
UP
RPM
A/I
Analog output
TI N
4. When automatic speed calibration is completed, the screen display of the calibrator will change from “E. XXXX” to “XXXX”.
AM E
MEMORY ON
Shop Manual - June 2013
A/I button WX215-1304009
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
Speed (rmp)
S1
1100
H1
1100
S2
1200
H2
1200
S3
1300
H3
1300
S4
1500
H4
1500
S5
1600
H5
1600
S6
1650
H6
1700
S7
1750
H7
1800
S8
1850
H8
1900
S9
1950
H9
2000
S10
2050
H10
2100
S11
2150
H11
2200
RI C
Level
AM E
Speed (rmp)
SA
NY
LA
TI N
Level
A
Engine speed reference (SY215C9)
Shop Manual - June 2013
6-5
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.2 Exhaust Gas Color - Test Testing tools ID
Model
Part Name
1
YDJ-2006
Smoke meter
2
SV-2TY
Opacimeter
A
CAUTION
RI C
● Do not touch any hot parts when mounting or dismounting the testing tools.
1) Put the filter paper into the smoke meter. 2) Insert the waste gas intake pipe into the exhaust pipe.
AM E
1. Measure with a smoke meter
TI N
3) Start the engine and keep the engine running until engine coolant temperature is within the operational range.
LA
4) When engine speed increases suddenly or is kept at high idle, direct exhaust gas through smoke meter to the filter paper.
NY
5) Remove the filter paper from the smoke meter. Read the smoke value through the apparatus provided.
SA
6) Remove the testing tools after measuring. Make sure the machine goes back to its normal state.
6-6
Shop Manual - June 2013
ZX215-1004002
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
2. Measure with an opacimeter
2) Open the opacimeter and preheat it for about 15 minutes.
LA
TI N
3) Start the engine and keep the engine running until engine coolant temperature is within the operational range.
ZX215-1004003
AM E
RI C
A
1) Mount the opacimeter onto the exhaust pipe by clamping it to the pipe outlet.
ZX215-1004004
NY
4) When engine speed increases suddenly or is kept at high idle, use the opacimeter to read the smoke value of exhaust gas.
SA
5) Remove the testing tools after measuring. Make sure the machine goes back to its normal state.
Shop Manual - June 2013
6-7
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.3 Valve Clearance - Adjust Service Standard (Unit: mm) Location
Service Item
Standard Value
Limits
Remedy
—
Valve clearance (engine cold)
0.4
—
Adjust
Tool Name and Shape
Part Number
Flat head screwdriver
Valve clearance adjustment (Carried on vehicle)
AM E
MH060008
Application
RI C
Symbol
A
Special Tools
Check and adjust valve clearance in cold state as per the following procedure:
LA
1. Remove the rocker arm cover.
TI N
6.3.1 Testing
Sight Glass
2. Turn the No.1 piston or the No.6 piston to the top dead center of compression stroke by following the procedure below.
SA
NY
● Turn the engine until the mark 16 on the flywheel aligns with the pointer on sight glass of the flywheel shell. Sight Glass
16
● Turn the No.1 piston or the No.6 piston to the top dead center of compression stroke.
Pointer
ZX215-1004009
6-8
Shop Manual - June 2013
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
NOTE:
RI C
A
When the rocker arm at the intake side and rocker arm at the exhaust side cannot be turned with hands, it is indicated that the piston has reached the top dead center of compression stroke. Turning the engine by one more turn, the top dead center of compression stroke of No.1 piston and No.6 piston interchanges.
Cylinder
1
INT EXH
2 ●
●
3 ○
●
4 ●
○
5 ○
●
6 ●
○
○ ○
AM E
3. When the No.1 piston is at the top dead center, adjust the valve clearance in a sequence marked by the black dot.
TI N
1) When a feeler gauge is used for such measurement, resistance to a moving feeler gauge in the clearance should be felt.
Valve clearance
LA
2) If the feeler gauge moves easily in the clearance, it is impossible to obtain accurate result.
NY
4. If the measured value is out of specification, readjustment shall be performed according to the following method.
SA
ZX215-1004007
Shop Manual - June 2013
6-9
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.3.2 Adjusting 1. To adjust valve clearance, loosen the locknut before adjusting the adjustment screw. Standard clearance is achieved when resistance to the feeler gauge is felt when pulling it out from the clearance.
Adjustment Screw
Locknut
RI C
A
2. After adjustment, stop the turning motion of the adjustment screw with a screwdriver, and tighten the locknut. Locknut: 16-24 N·m {1.7±2.5 kgf·m}
4. Check the clearances again with the feeler gauge. Readjustment should be made if the value is out of specification.
ZX215-1004006
Adjustment Screw
SA
NY
LA
TI N
5. When the engine is carried in vehicle, using to turn the adjustment screw will make your work easy.
Valve Clearance
AM E
3. Go on with the next step until all valve clearances marked with a black dot have been adjusted.
6-10
Shop Manual - June 2013
ZX215-1004008
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.4 Compression Pressure - Measure Service Standard Location
Standard Value
Limits
Remedy
Each cylinder (at 200 2550kPa {26kgf/cm²} 1960 kPa {20kgf/cm²} Compression rpm) Differential pressure pressure — Below 390 kPa {4kgf/cm²} between cylinders
Test Test
A
—
Service Item
Tool Name and Shape Compression pressure gauge connector
Part Number
AM E
Symbol
RI C
Special Tool
MH061460
A M14×1.5
A
Application
Measuring compression pressure
TI N
1. Reduction of compression pressure can be an indication for engine overhaul.
NY
LA
2. Check the compression pressure regularly and pay attention to its variation from time to time. In addition, in a new vehicle or when new parts are installed for replacement, the pressure may be higher due to running-in of the piston ring, valve seat, etc. The pressure will become normal as the parts wear.
SA
3. Before testing, make sure engine oil, start motor and battery are in normal condition. 4. Set the machine as per the following: 1) Preheat the engine until engine coolant temperature reaches 75~85°C. 2) Switch off all lamps and auxiliary devices. 3) Place the gear lever in a neutral position. 5. Remove the entire fuel injector.
Shop Manual - June 2013
6-11
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6. Cover the fuel injector mounting opening with cloth. 7. Activate the start motor in order to run the engine. Check if the cloth is stained by foreign substances.
Rags Injector mounting hole
A
8. Determine the problem with the engine according to the substances (engine oil and/ or coolant) on the cloth.
CAUTION
When coolant and/or engine oil is found attached to the cloth, running the engine may cause the hot coolant and engine oil to squirt out through the mounting hole of the fuel injector. This is very dangerous. Never touch or look into the fuel injector mounting hole when the engine is running.
TI N
9. Mount the gasket and tool to the fuel injector mounting hole and fix them with the injector cap. Install the compression pressure gauge.
ZX215-1004005
AM E
2) When engine oil and coolant are found, it might be cracking of cylinder. Replace the crankcase.
RI C
1) When engine oil is found, it might be improper sealing caused by piston ring. Check the piston ring.
LA
10. Start the engine and measure the compression pressure of each cylinder. Calculate the differential pressure between the cylinders.
NY
11. When the compression pressure and the differential pressure between cylinders deviate from their limits, inject a small amount of engine oil through the fuel injector mounting hole, and measure the compression pressure again.
SA
● If the compression pressure is higher, it is probably due to worn or damaged piston ring or cylinder inner surface. ● If the compression pressure is still low, it is probably due to stuck valve or improper seating, or improperly mounted gasket of cylinder head.
6-12
Shop Manual - June 2013
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.5 Fuel Injection Timing - Test and Adjust Service Standard Location
Service Item
Standard Value
Limits
Remedy
—
Fuel injection timing (BTDC)
14°
—
Adjust
Tightening Torque (Unit: N·m) Parts Tightened
Tightening Torque
—
Union nut
24
—
Lock plate
3.4~4.9
—
—
Lock seat - delivery valve
39~44
—
—
Nut (used for mounting fuel injection pump)
29~39
—
Symbol
Tool Name and Shape
TI N
Universal Extension Rod A 14
RI C
AM E
Special Tool
Remark
A
Symbol
—
Part Number
Application
MH061099
Testing and adjusting the fuel injection timing
6.5.1 Testing
LA
A
SA
NY
1. Remove the injection pipe, lock plate, lock seat, retainer ring and delivery valve from the No.1 cylinder of the fuel injection pump. 2. After removal of all the parts, install the lock seat.
Injection pipe Lock Seat Retainer Ring Spring Delivery Valve
Lockplate
NOTE: The removed parts should be put into light oil in order to keep them free from dust.
ZX215-1004011
Shop Manual - June 2013
6-13
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
3. Install the prepared injection pipe onto No.1 cylinder. Keep the other end of the injection pipe downward so that fuel flowing out can be observed.
Injection pipe
RI C
A
4. Turn the crankshaft manually over 180° in the forward direction to locate No.1 cylinder in a position that is about 30° from the top dead center of compression stroke.
5. The main pump is used to transfer fuel. As the fuel flows out of the injection pipe, turn the engine manually in the forward direction.
TI N
NOTE: The engine positioning lever on the governor must be placed in the starting position.
AM E
ZX215-1004012
LA
6. When the fuel coming out of the injection pipe is about to stop, continue to turn the engine slowly until the fuel stops coming out.
Injection pipe
Priming pump
Positioning Lever ZX215-1004013
NY
7. Make sure that the flywheel mark and pointer are one degree before the fuel injection timing.
SA
Pointer
ZX215-1004014
6-14
Shop Manual - June 2013
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
NOTE: When the fuel injection timing deviates from its standard value, the following steps must be followed for adjustment.
6.5.2 Adjusting 1. Loosen the mounting nuts of fuel injection pump.
A
A: 4 nuts (on the flange)
AM E
RI C
B: 1 nut
B
TI N
A
2. Targeted at the pointer, activate the injection pump in order to adjust injection timing.
ZX215-1004015
Injection Pump
Pointer ZX215-1004016
SA
NY
LA
3. Tighten the nuts to specific torque. Measure the injection timing again.
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6-15
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
4. When the injection timing is slow, move the injection pump toward the crankcase (direction C).
C
5. When the injection timing is fast, move the injection pump away from the crankcase (direction D).
D
RI C
A
Injection Pump
6. When injection timing meets the standard value, install the delivery valve, spring, retainer ring, lock seat, lock plate and injection pipe.
LA NY SA 6-16
Lock Seat
Injection pipe
TI N
7. Tighten all the parts to specific torques.
AM E
ZX215-1004017
Shop Manual - June 2013
Lockplate
ZX215-1004018
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.6 Engine Oil Pressure - Measure Service Standard Location — —
Service Item Engine oil pressure at 70~90°C
Standard Value
Limits
Min. speed, unloaded
145 KPa
49 KPa
Max. speed, unloaded
295 KPa~490 KPa
195 KPa
A
Tightening Torque (Unit: N·m) Part Tightened
Tightening Torque
—
Engine oil pressure switch
7.8~12
Symbol
Location
Part Number
Amount
—
Threads of pressure switch
A420300000032
As necessary
LA
TI N
1. Remove the engine oil pressure switch.
AM E
Lubricant/Sealant
Engine cold
Engine Oil Pressure Switch
NY
ZX215-1004019
2. Mount the adaptor to where the engine oil pressure switch has been removed. Mount the engine oil pressure gauge to the adaptor.
SA
Remark
RI C
Symbol
Pressure Gauge
Adaptor ZX215-1004020
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6-17
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
3. Preheat the engine until engine oil temperature reaches 70-90°C. 4. Measure respectively the unloaded engine oil pressure at minimum speed and maximum speed.
A
5. If the measured value is lower than the specified standard value, check the entire lubrication system.
RI C
6. After measuring, apply sealant to the threads of pressure switch. Tighten the pressure switch to specific torque.
SA
NY
LA
TI N
Then engine oil pressure switch must be installed when the engine is cold.
AM E
NOTICE
6-18
Shop Manual - June 2013
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.7 Engine Speed Sensor - Adjust
1. Screw on the sensor (1) until its end contacts with ring gear tip (2) of the flywheel. 2. Unscrew the sensor some degrees.
RI C
AM E
1
A
NOTE: Remove the engine speed sensor (1) before adjusting. Check for presence of metal chips and for damaged sensor top. Restore the sensor.
1
ZXT215-1004001
2
TI N
Degrees: 1.2~1.4 turns Adjust the clearance (a) between the sensor end and the flywheel edge to 2±0.2 mm.
LA
3. Tighten the sensor (1) with the nut (3). Nut: 49.0~68.6 N·m {5~7kg·m}
3
a ZX215-1004021
SA
NY
4. Make sure that the engine speed is displayed properly on the control panel after adjustment.
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6-19
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.8 A/C Compressor Belt Tension - Test and Adjust 6.8.1 Testing Press the intermediate point of the belt between the drive pulley and the compressor pulley with a finger force of about 58.8 N(6kgf), and measure deflection (A) of the belt, which shall be 5~8 mm (0.20 in~0.31in).
Compressor Belt Pulley
Drive Pulley
RI C
A
A
AM E
ZX215-1004022
6.8.2 Adjusting NOTE: If the belt deflection is abnormal, adjust it according to the following procedure.
TI N
1. Loosen the bolts (1) and (2).
4 1
2. Move the compressor (3) and the bracket (4) together to adjust belt tension.
LA
3. After positioning the compressor (3), tighten the bolts (1) and (2).
2
4. Check belt tension again after adjustment.
NY
ZXT215-1004002
SA 6-20
3
Shop Manual - June 2013
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
Reference Use a tensiometer to check the compressor belt tension. Used Belt
637±108 N {65±11 kgf}
441±88.2 N {45±9 kgf}
A
New Belt
● Contact local Sany dealer and replace the belt in case of the following conditions.
TI N
● The fan belt has been stretched and little margin is left for adjustment.
AM E
● Check each belt for damage. Check the V-groove and the V-belt for wear. In addition, it is especially important to keep the V-belt free from friction with bottom of the V-groove.
RI C
NOTE:
● Cuts or cracks are found in the belt. ● Abnormal sliding or noise.
SA
NY
LA
● When a new belt is mounted, readjust the belt tension after one hour operation.
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6-21
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.9 Swing Bearing Clearance - Measure Measuring tool Symbol
Part Number
Part Name
H
60033930
Dial gauge
RI C
A
● The following steps are to be followed when measuring the clearance of swing bearing.
● Park your machine on a level ground. Lower your work equipment to the ground. ● Do not put your hands or feet under the undercarriage during measurement.
AM E
CAUTION
TI N
1. Fix the dial gauge (H) to the track frame and apply the probe to the lower end of the outer race.
LA
2. Place the work equipment to the maximum reach position. Raise the bucket to a height that the bucket tips and the swivel table bottom are on the same level.
H
NY
At the moment, the front of upper structure lowers while the rear rises. ZX215-1004023
3. Set the dial gauge (H) to zero.
SA
4. Set the arm almost perpendicular to the ground and lower the boom until the front track shoe floats. At the moment, the front of upper structure rises while the rear lowers. 5. Read the dial gauge (H). 6. Restore the machine to the condition of
ZX215-1004024
6-22
Shop Manual - June 2013
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
step 2. Check the dial gauge (H) to see if it reads zero.
150～200mm
The value indicated by the dial gauge (H) is the clearance of the bearing.
A
For more information, see “Swing bearing” on page 4-13.
ZX215-1004025
SA
NY
LA
TI N
AM E
RI C
Repeat step 3 through step 5 if the dial gauge (H) reads a value other than zero.
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6-23
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.10 Track Tension - Test and Adjust 6.10.1 Testing 1. Move your machine forward for a distance that is equal to the length of track on the ground. Keep running the engine at low idle. Park your machine slowly.
3
2 a
ZX215-1004026
SA
NY
LA
TI N
● Max. clearance (a): 10~30 mm (0.4~1.2 in)
6-24
RI C
3. Measure the maximum clearance (a) between the upper surface of track and the lower edge of the straight bar.
1
AM E
NOTE: A straight angle steel bar is recommended for this purpose as it has good resistance to bending strain.
A
2. Place a straight bar on the track over idler (1) and carrier roller (2).
Shop Manual - June 2013
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.10.2 Adjusting ● If track tension is incorrect, make adjustment as per the following instruction.
CAUTION
RI C
A
● Do not loosen the valve over one turn. If the valve is loosened too much, the grease under high pressure may cause the valve to eject.
1) Loosen the valve (1) to discharge grease. Tighten the valve after discharging. 2) Check the track tension again as per the above method after adjustment.
AM E
1. Reduce track tension
TI N
2. Increase track tension 1) Add grease through the grease fitting (2) with a grease gun.
1
2 ZXT215-1004003
LA
2) Check the track tension again as per the above method after adjustment.
SA
NY
NOTE: Add grease until the gap (b) between the idler guide and the track frame end becomes zero. If the tension is till low, it indicates that the pins and bushings are seriously worn. Replace the pins and bushings, or remove a piece of track shoe.
b ZX215-1004027
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6-25
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.11 Hydraulic Pressure in Hydraulic Circuits - Test and Adjust Testing and adjusting tools ID —
Part Number
Part Name
60038932
Hydraulic Tester
B210770000084
Adaptor
RI C
A
NOTE: The hydraulic pressure in work equipment, swing and travel (hydraulic pump output) circuits can be viewed on the monitor.
CAUTION
TI N
● Lower the work equipment to the ground and stop the engine. Operate the control levers for several times to release the residual pressure in hydraulic circuits.
AM E
6.11.1 Measuring
LA
● Open the butterfly nut on the breather valve and press the relief button to release pressure in the hydraulic tank. 1. Preparatory work before measuring
NY
1) Remove the plug (1) and plug (2) for measuring the hydraulic pressure. ● Plug (1): For oil circuit of rear pump 1
SA
● Plug (2): For oil circuit of front pump
2
2) Install the priming adaptor and connect it to the hydraulic tester. ● Use an oil pressure gauge with a capacity of 40 MPa {408 kgf/cm²}.
3) Start the engine and keep it running until the hydraulic pressure rises to a point within the operational range.
6-26
Shop Manual - June 2013
ZX215-1004028
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
2. Measurement of unloading pressure 1) Start the engine. 2) Measure the hydraulic pressure when the engine is running at high idle and all control levers are in a neutral position.
RI C
A
NOTE: The hydraulic pressure indicated is the pressure when the unloading valve unloads.
1) Start the engine and move the cylinder to be measured to its stroke end.
TI N
2) Measure the hydraulic pressure when the engine is running at high idle and the cylinder is in relief condition.
AM E
3. Measurement of work equipment pressure at relief
LA
NOTE: The hydraulic pressure indicated is the pressure when the main relief valve is in relief condition.
4. Measurement of swing pressure at relief
SA
NY
1) Start the engine. Reach out the work equipment as far as possible. Lower the work equipment on the ground in order to restrict swinging. 2) Measure the hydraulic pressure when the engine is running at high idle and the swing circuit is in relief condition. NOTE: The hydraulic pressure indicated is the pressure when the swing motor relief valve is in relief condition. NOTE: The relief pressure of swing motor is lower than the main relief pressure.
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6-27
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
5. Measurement of travel pressure at relief 1) Start the engine and lock the travel mechanism. NOTE: Place the pin (1) between the sprocket and the track frame to lock the travel mechanism.
A
2) Measure the hydraulic pressure when the engine is running at high idle and the travel circuit is in relief condition.
RI C
1
NOTE: The hydraulic pressure indicated is the pressure when the main relief valve is in relief condition. When the travel circuit is in relief condition, the pressure indicated is always the pressure at high relief.
AM E
ZXT215-1004004
6.11.2 Adjusting
TI N
NOTE: The boom relief valve cannot be adjusted. 1. Adjustment of main relief pressure
LA
NOTE: If the high relief pressure is abnormal, adjust the high pressure setting of the main relief valve (3) as per the following.
3
NY
1) Disconnect the pilot hose. 2) Loosen the locknut (4). Turn the adjustment screw (5) to adjust the pressure.
ZXT225-1104002
SA
Pressure rises as the screw turns right. Pressure drops as the screw turns left. Each turn of the screw equals about: 12.5 MPa {128 kgf/cm²}
4
Locknut: 53.5±4.9 N·m {5.5±0.5 kgf·m} 5
ZX215-1004029
6-28
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Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
3) Check the pressure again after adjustment. Measure the pressure according to the procedure described above. ● Connect the pilot hose before measuring the pressure.
RI C
A
● Adjustment of the high pressure setting side will affect the low pressure setting side. The low pressure setting side is, therefore, to be adjusted too.
NOTE: If the swing relief pressure is abnormal, adjust the swing motor relief valve (6) as per the following.
TI N
1) Loosen the locknut (7). Turn the adjustment screw (8) to adjust the pressure.
AM E
2. Adjustment of swing relief pressure
Pressure rises as the screw turns right. Pressure drops as the screw turns left.
Locknut:
LA
Each turn of the screw equals about: 6.71 MPa { 68.4 kgf/cm²}
78-103 N·m{8.0-10.5 kgf·m}
6
7
8 ZXT225-1104003
SA
NY
2) Check the pressure again after adjustment. Measure the pressure according to the procedure described above. 7
8 ZX215-1004030
Shop Manual - June 2013
6-29
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.12 Control Circuit Oil Pressure - Test and Adjust Testing and adjusting tools
—
Part Number
Part Name
21008760
Hydraulic Tester
B210770000084
Adaptor
A
ID
RI C
6.12.1 Testing
● Lower the work equipment to the ground and stop the engine. Operate the control levers for several times to release the residual pressure in hydraulic circuits.
TI N
● Open the butterfly nut on the breather valve and press the relief button to release pressure in the hydraulic tank.
AM E
CAUTION
LA
1. Remove the plug (1) for measuring the hydraulic pressure. 2. Install the priming adaptor and connect it to the hydraulic tester.
NY
Use an oil pressure gauge with a capacity of 6 MPa{61 kgf/cm²}
SA
3. Start the engine and keep it running until the hydraulic pressure rises to a point within the operational range. 4. Measure oil pressure when the engine is running at high idle and all control levers are in a neutral position.
6-30
Shop Manual - June 2013
1
2 ZXT215-1004007
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.12.2 Adjusting 1. If the measurement is less than 3.5 kgf/ cm², loosen the retaining nut (2) and screw in adjusting stud (3). Watch the change of readings on the pressure gauge at the same time. Tighten the retaining nut (2) when proper pressure value is achieved.
3
ZX215-1004031
SA
NY
LA
TI N
AM E
RI C
A
2. Remove all the tools after measurement and make sure the machine returns to its normal condition.
2
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6-31
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.13 Solenoid Valve Output Pressure - Measure Measuring tools ID —
Part Number
Part Name
21008760
Hydraulic Tester
B210770000084
Adaptor
RI C
A
NOTE: Make sure that the initial pressure of control oil circuit is normal before measuring the output pressure of solenoid valve.
● Lower the work equipment to the ground and stop the engine. Operate the control levers for several times to release the residual pressure in hydraulic circuits.
AM E
CAUTION
TI N
● Open the butterfly nut on the breather valve and press the relief button to release pressure in the hydraulic tank.
No.
LA
1. Disconnect the hose of solenoid valve to measure the pressure at the outlet. Solenoid Valves to be Measured Solenoid valve - high/low travel speed
2
4
Solenoid valve - swing priority Solenoid valve - bucket confluence/diffluence Solenoid valve - boom priority
5
Solenoid valve - pilot lockout
SA
3
NY
1
5
4
3
2
1
A
2. Install a tee to location (A) on each solenoid valve and connect the hose. WXT215-1206001G
3. Mount the adaptor onto the tee and connect it to the hydraulic tester. Use a hydraulic tester with a capacity of 6 MPa{61 kgf/cm²} .
6-32
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Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
4. Start the engine and keep it running until the hydraulic oil temperature rises to a point within the operational range. 5. Run the engine at full speed. Operate the control levers to open or close each solenoid valve, and measure the pressure.
RI C
A
● The function of each solenoid valve can be checked through the monitor's monitoring function. (This is a special function of the monitor.)
High speed travel Output Pressure
OFF (de-energize)
0 {0}
ON (energize)
3.9~4.1 MPa{39~41 kgf/cm²}
TI N
Solenoid Valve
Swing priority
Output Pressure
OFF (de-energize)
0 {0}
LA
Solenoid Valve
ON (energize)
AM E
● When each output pressure reads the following values, the solenoid valve is normal.
3.0~3.9 MPa{30~39 kgf/cm²}
NY
6. Remove all measuring tools after measurement. Make sure that the machine returns to its normal condition.
SA
Table of functioning state - pilot lock solenoid valve Functioning State
Lockout control
Function
Lock
OFF
Free
ON
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6-33
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.14 Pilot Valve Output Pressure - Measure Measuring tools ID —
Part Number
Part Name
21008760
Hydraulic Tester
B210770000084
Adaptor
RI C
A
NOTE: Make sure that the initial pressure of control oil circuit is normal before measuring the output pressure of pilot valve.
7
Oil Circuit Measured Bucket DUMP
2
Travel right
8
Arm IN
3
Arm OUT
9
Swing
4
Bucket DIG
5
Boom DOWN
6
Boom UP
No.
TI N
1
Oil Circuit Measured Travel left
No.
AM E
1. Remove the pilot pressure switch.
LA
2. Install the adaptor and connect it to the hydraulic tester.
9
NY
Use a hydraulic tester with a capacity of 6 MPa {61kgf/cm²}
SA
3. Start the engine and keep it running until the hydraulic oil temperature rises to a point within the operational range. 4. Measure the output pressure when the engine is running at high idle and all control levers of the tested circuit are in neutral position or at full stroke.
6-34
Shop Manual - June 2013
8 7
2 1 4 3 5 6 ZXT225-1104005
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
Control Lever
Hydraulic Pressure
Neutral
0{0} Close to the average initial pressure of oil control circuit (See Table of Standard Values)
Full stroke
A
NOTE: When the measured output pressure reads the following values, the pilot valve is normal.
SA
NY
LA
TI N
AM E
RI C
5. Remove all measuring tools after measurement. Make sure that the machine returns to its normal condition.
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6-35
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.15 Pilot Valves (Work Equipment and Swing) - Adjust ● If the play of work equipment or swing control lever is excessive, make adjustment as per the following procedure. 1. Remove the work equipment and swing pilot valve assembly. 2. Remove the rubber sleeve (1).
A
2
RI C
3. Loosen the locknut (2). Screw on the disc (3) until it contacts with the four heads of plunger (4).
3
1
4. When the disc (3) is fixed, tighten the locknut (2) to specified torque. Locknut:
5. Install the rubber sleeve (1).
TI N
98~127 N·m {10~13 kgf·m}
AM E
NOTE: Do not move the plunger.
SA
NY
LA
6. Install the work equipment and swing pilot valve assembly.
6-36
Shop Manual - June 2013
4
ZX215-1004032
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.16 Work Equipment Hydraulic Drift - Test NOTE: If hydraulic drift exists in the work equipment cylinder, check it according to the following procedure and determine whether the failure lies in the cylinder seal or in the control valve.
A
1. Boom and bucket cylinders
RI C
1) Park your machine in an attitude as shown and stop the engine.
2) Operate the control levers so that the
ZX215-1004033
TI N
boom is in the raising position and the bucket in the digging position.
AM E
NOTE: Load the bucket fully with earth or impose rated load on the bucket.
LA
● If the lowering speed rises, the problem lies in the cylinder seal. If nothing changes, the problem lies in the control valve. ● Operate the control levers with engine start switch in the ON position.
NY
● If the pressure in accumulator drops, charge the accumulator again by running the engine for about 10 seconds.
SA
2. Arm cylinder
Shop Manual - June 2013
6-37
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
1) Park your machine in an attitude as shown. The distance between the arm cylinder and the digging stroke end is 100 mm. Stop the engine. 2) Operate the control levers in order to place the arm in the digging position.
A
● If the lowering speed rises, it is failure of the cylinder seal. If nothing changes, it is failure of the control valve.
ZX215-1004034
[Reference]
TI N
If hydraulic drift is caused by failure of the cylinder seal, the reason for lowering speed increase during the above operation is described below:
AM E
● If the pressure in accumulator drops, charge the accumulator again by running the engine for about 10 seconds.
RI C
● Operate the control levers with engine start switch in the ON position.
LA
1) If the machine is set in the above position (where the holding pressure is applied to the bottom side), the oil leaks from the bottom side to the head side. The pressure in the head side is increased.
SA
NY
2) As the pressure in the head side decreases, the pressure in the bottom side increases in order to keep it balanced. This process is repeated until balance is reached at a certain level depending on the amount of leakage. 3) When the pressure is balanced, the lowering speed decreases. If the control levers are operated according to the above procedure, the oil circuit in the head side opens to the drain circuit (while the bottom side is
6-38
Shop Manual - June 2013
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
closed by a check valve), and the oil flows to the drain circuit from the head side. As a result, the lowering speed increases. 3. Checking the pilot valve
A
While the pressure in the accumulator is high, set the hydraulic lockout control in the LOCKED/FREE position and measure the hydraulic drift respectively.
RI C
● Operate the control levers with engine start switch in the ON position.
SA
NY
LA
TI N
● If there is a difference in hydraulic drift between the LOCKED position and the FREE position, it the failure (internal fault) of the pilot valve.
AM E
● If the pressure in accumulator drops, charge the accumulator again by running the engine for about 10 seconds.
Shop Manual - June 2013
6-39
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.17 Residual Pressure in Hydraulic Circuit - Release CAUTION
RI C
TI N
1. Stop the engine, loosen the butterfly nut on the breather valve, and press the release button to release the pressure in hydraulic tank.
AM E
NOTE: Even if the swing motor circuit and the travel motor circuit are free from residual pressure, they will be influenced by the internal pressure of hydraulic tank. The breather valve must therefore be opened to release pressure prior to such operation.
A
● Release the residual pressure in the hydraulic circuit before disconnecting the lines between the hydraulic cylinders or between the hydraulic motor and the control valve.
2. Turn the engine start switch to the ON position and operate the control levers for several times.
LA
● The pilot lock valve must be energized. Operate the control levers with the engine start switch in the ON position.
NY
● The pressure in accumulator will be released after the control levers have been operated 2 or 3 times.
SA
3. Start the engine and keep the engine running at low idle for about 10 seconds in order to increase the pressure in accumulator. Stop the engine. 4. Repeat the above step 2 through step 3 several times.
6-40
Shop Manual - June 2013
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.18 Oil Leakage - Measure 1. Measure oil leakage from boom cylinder 1) Start the engine and keep it running until the hydraulic oil temperature is within the operational range. Fully extend the boom cylinder.
1
RI C
A
NOTE: Release the residual pressure in the circuits.
2) Disconnect the hose (1) on the cylinder head side and plug the hose end with a cap. NOTE: Be careful not to disconnect the hose on the cylinder bottom side.
ZXT215-1004010
AM E
See “Residual Pressure in Hydraulic Circuit - Release” on page 6-40.
TI N
3) Start the engine and apply relief pressure to the bottom side of the cylinder while the engine is running at high idle.
LA
4) Hold this condition for 30 seconds. Measure oil leakage for one minute.
SA
NY
5) Make sure that the machine returns to its normal condition after measurement.
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6-41
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
2. Measure oil leakage from arm cylinder 2
1) Start the engine and keep it running until the hydraulic oil temperature is within the operational range. Fully extend the arm cylinder. NOTE: Release the residual pressure in the circuits.
RI C
A
See “Residual Pressure in Hydraulic Circuit - Release” on page 6-40.
ZXT225-1104007
NOTE: Be careful not to disconnect the hose on the cylinder bottom side. 3) Start the engine and apply relief pressure to the bottom side of the cylinder while the engine is running at high idle.
AM E
2) Disconnect the hose (2) on the cylinder head side and plug the hose end with a cap.
TI N
4) Hold this condition for 30 seconds. Measure oil leakage for one minute.
SA
NY
LA
5) Make sure that the machine returns to its normal condition after measurement.
6-42
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Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
3. Measure oil leakage from bucket cylinder 1) Start the engine and keep it running until the hydraulic oil temperature is within the operational range. Fully extend the bucket cylinder.
A
NOTE: Release the residual pressure in the circuits.
RI C
See “Residual Pressure in Hydraulic Circuit - Release” on page 6-40. 2) Disconnect the hose (3) on the cylinder head side and plug the hose end with a cap.
ZXT225-1104008
TI N
3) Start the engine and apply relief pressure to the bottom side of the cylinder while the engine is running at high idle.
AM E
NOTE: Be careful not to disconnect the hose on the cylinder bottom side.
3
4) Hold this condition for 30 seconds. Measure oil leakage for one minute.
SA
NY
LA
5) Make sure that the machine returns to its normal condition after measurement.
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6-43
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
4. Measure oil leakage from swing motor 1) Fully extend the work equipment. Lower the bucket on the ground and raise the machine slightly. Secure machine from rotating clockwise or counter clockwise while testing. Stop the engine.
A
2) Disconnect the hose (4) and the hose (5). Plug the hose ends with caps.
4
TI N
● After the first measurement, turn the upper structure 180°and measure the leakage again in the same way.
5
AM E
● Hold the condition described in step 3) for 30 seconds. Measure oil leakage for one minute.
RI C
3) Start the engine and apply relief pressure to the bottom side of the swing motor while the engine is running at high idle. Measure oil leakage under this condition.
SA
NY
LA
4) Make sure that the machine returns to its normal condition after measurement.
6-44
Shop Manual - June 2013
ZXT225-1104006
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
5. Measure oil leakage from travel motor 1) Remove the cover of the travel motor. 2) Start the engine and lock the travel mechanism.
A
NOTE: Insert pin (1) between the sprocket and the track frame to lock the travel mechanism.
RI C
1
LA
TI N
4) Start the engine and apply relief pressure to the bottom side of the travel motor while the engine is running at high idle. Measure oil leakage under this condition.
AM E
3) Disconnect the drain hose (6) of the travel motor. Plug the hose end with a cap.
ZXT215-1004004
WARNING
ZXT215-1004014
NY
● During measurement, mis-operation of the control levers can cause serious accidents. Make sure that all signals are given correctly.
6
SA
● Hold the condition described in step 4) for 30 seconds. Measure oil leakage for one minute. ● Rotate the motor slightly. Change the positions of the valve plate and the travel motor and of the cylinder and piston. Repeat the measurement several times.
5) Make sure that the machine returns to its normal condition after measurement.
Shop Manual - June 2013
6-45
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
6.19 Air in Each Component - Bleed Air bleeding procedures
● Cleaning filter element ● Replacing return filter element ● Repairing/replacing hydraulic pump ● Removing suction piping ● Repairing/replacing control valve ● Replacing cylinder
3
Bleed air from hydraulic pump
Starting engine
Bleed air from cylinder
○
○
○
○ ○
○
○
○
○
○
● Removing cylinder piping ● Replacing swing motor
○
● Removing swing motor piping ● Replacing travel motor
5
6
Bleed air Bleed air from swing form travel motor motor
○ (Note)
Starting operation
○ (Note)
○ ○
○ ○
○
○
○
○
○ ○
○
TI N
● Removing travel motor piping
4
A
● Replacing hydraulic oil
2
RI C
Contents of work
1
AM E
Air bleeding item
LA
NOTE: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained. 1. Bleed air from hydraulic pump
NY
1) Loosen the air bleeder (1) and check that oil oozes out through the air bleeder. 1
SA
2) Tighten the air bleeder (1) if oil is seen. Bleeder: 7.8~9.8 N·m{0.8~1.0 kgf·m}
NOTE: Run the engine at low idle for 10 minutes after bleeding the air according to the above procedure. ZXT215-1004015
6-46
Shop Manual - June 2013
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
2. Bleed air from hydraulic cylinder 1) Start the engine and keep the engine running at low idle for 5 minutes. 2) Raise or lower the boom 4 or 5 times with the engine running at low idle.
A
NOTE: Be careful not to apply relief pressure. Stop the piston when the rod is about 100 mm before stroke end.
5) Bleed air from arm cylinder and bucket cylinder by performing step 2) through step 4).
AM E
4) While running the engine at low idle, move the piston rod to the stroke end and apply relief pressure.
RI C
3) Repeat step 2) with the engine running at high idle.
SA
NY
LA
TI N
NOTE: When a new cylinder is installed for replacement, bleed the air from the new cylinder before mounting it to the work equipment. Especially the boom cylinder, once mounted to the work equipment, its piston rod is unable to reach its stroke end in lowering operation. Therefore, the air must be bled from the boom cylinder before it is mounted to the work equipment.
3. Bleed air from swing motor 1) Start the engine and run the engine at low idle. 2) Bleed air from the swing motor by turning the upper structure slowly.
Shop Manual - June 2013
6-47
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
4. Bleed air from travel motor 1) Start the engine and run the engine at low idle. 2) Loosen the bleeder (2) and check that oil oozes out through the air bleeder. 3) Tighten the air bleeder (2) if oil is seen.
A
Bleeder:
RI C
27.5~35.3 N·m{2.8~3.6 kgf·m}
2
SA
NY
LA
TI N
AM E
ZXT215-1004016
6-48
Shop Manual - June 2013
Testing and Adjusting
SY195/205/215/225C9 Crawler Hydraulic Excavator
Table of monitored items Monitored Item
Unit
Remark
Graph
High/Low Travel Speed Selection
Graph
Auto Idle Selection
Graph
Engine Speed
r / min
Pressure - Rear pump
Kg
Current - Proportional Valve (Solenoid, Front pump)
mA
Current - Proportional Valve (Solenoid, Rear pump)
mA
Pilot Pressure - Boom Raise
Kg
Pilot Pressure - Boom Lower
Kg
Pilot Pressure - Arm In
Kg
Pilot Pressure - Arm Out
Kg
Pilot Pressure - Bucket Dump Pilot Pressure - Swing Pilot Pressure - Travel Left
LA
Pilot Pressure - Travel Right
Kg
TI N
Pilot Pressure - Bucket Curl
Kg Kg Kg Kg
Bucket Confluence
ON / OFF
Swing Priority
ON / OFF
Hi/Lo Speed Switching
ON / OFF
NY
Solenoid Valve 1
RI C
Kg
AM E
Pressure - Front pump
A
Controller Mode Selection
V
Voltage - Motor Position
V
Temperature - Engine Coolant
°C
Gauge reading
Temperature - Hydraulic oil
°C
Gauge reading
SA
Voltage - Fuel Control Dial
Pressure - Engine Oil
KPa
Shop Manual - June 2013
6-49
SY195/205/215/225C9 Crawler Hydraulic Excavator
BSLAN AYNL AT K IN PAA M GERI E CA
Testing and Adjusting
6-50
Shop Manual - June 2013
RI C
Troubleshooting
A
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
7 Troubleshooting
SA
NY
LA
TI N
AM E
7.1 Points to Remember When Troubleshooting ........................................................... 7-3 7.2 Troubleshooting Procedures .................................................................................... 7-5 7.3 Connector Location and Electrical Circuit Diagram ................................................. 7-8 7.3.1 Connector location layout ............................................................................ 7-12 7.3.2 Electrical element circuit diagram (cab circuit)............................................. 7-18 7.3.3 Electrical control circuit diagram (engine circuit).......................................... 7-20 7.3.4 Electrical control circuit diagram (sensor and solenoid valve circuit) ........... 7-22 7.3.5 SWP type connector .................................................................................... 7-23 7.3.6 A/AMP type connector ................................................................................. 7-24 7.3.7 DT type connector ....................................................................................... 7-25 7.4 Failure Symptoms and Troubleshooting Codes ..................................................... 7-26 7.5 Troubleshooting with an Event Code ..................................................................... 7-28 7.6 Troubleshooting of Electrical System (E - Mode)................................................... 7-63 7.7 Troubleshooting of Hydraulic and Mechanical Systems (H - Mode) ...................... 7-93
Shop Manual - June 2013
7-1
Troubleshooting
SA
NY
LA
TI N
AM E
RI C
A
SY195/205/215/225C9 Crawler Hydraulic Excavator
7-2
WARNING
Read and understand all safety precautions and instructions in this manual before reading any other manuals provided with this machine and before operating or servicing the machine. Also read the safety information on machine decals before performing any operations. Failure to do so can cause machine damage, personal injury or death.
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
7 TROUBLESHOOTING 7.1 Points to Remember When Troubleshooting ● Stop the machine in a level ground, and check that lock pins, blocks, and parking brake are securely fitted.
A
● When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near.
RI C
● If the radiator cap is removed when the engine is hot. Hot coolant may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting. ● Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
AM E
● When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. ● When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. It will also cause a waste of man-hours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator.
When carrying out troubleshooting, important point is to understand the structure and function.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure.
LA
TI N
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure.
SA
NY
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: ● Parts that have no connection with the failure or other unnecessary parts will be disassembled. ● It will become impossible to find the cause of the failure.
2. Points to ask user or operator: 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before
Shop Manual - June 2013
7-3
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
3. Check before troubleshooting 1) Check the oil level. 2) Check for any external leakage of oil from the piping or hydraulic equipment.
● Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. ● The basic procedure for troubleshooting is as follows.
A
6) Has the same kind of failure occurred before?
5. Troubleshooting
1) Start from the simple points.
RI C
the failure? When were these repairs carried out?
2) Start from the most likely points.
4) Check the stroke of the control valve spool.
3) Investigate other related parts or information.
5) Other maintenance items can be checked externally, so check any item that is considered to be necessary. 4. Confirming failure
6. Measures to remove root cause of failure ● Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
TI N
● Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc.
AM E
3) Check the travel of the control levers.
SA
NY
LA
NOTE: When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse.
7-4
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
7.2 Troubleshooting Procedures If some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting No. and proceed to the explanations for diagnosis. Follow six steps listed below to diagnose and analyze for troubleshooting, and find the causes and work out the corresponding methods. d. What kind of trouble did machine have before?
RI C
A
1. Read related technical manuals in detail. Have a knowledge of related system, principle of operation, and structure, function and technical specification of parts.
For example: Which parts have been repaired or replaced? e. What has been done after troubles take place and how about the reaction?
Before checking, ask related person, i.e. the operator for all information about the failure.
f. Will the trouble reoccur? Does the trouble occur regularly?
3. Check before starting
TI N
a. Current working condition of machine (Whether machine is operated properly).
AM E
2. Ask operator
LA
b. When troubles are found and what kind of operation does machine perform at that time?
SA
NY
c. Development of troubles (Whether troubles are becoming severer or occur for the first time.)
Before starting troubleshooting, check the operator's records on operation, maintenance and service of the machine. Understand whether related personnel has done wrong in operation, maintenance and service. Check for wrong operation and maintenance at the same time.
Shop Manual - June 2013
7-5
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
— — —
Tighten or replace
LA
NY
A
Add fuel Clean, drain Add oil Clean, drain Add oil Add oil Add water Clean or replace Replace Add oil
— — —
1. Check battery voltage (with engine stopped) 20-30V 2. Check electrolyte level — 3. Check for discolored, burnt, exposed wiring — 4. Check for missing wiring clips and hanging wiring — 5. Check for wet wires (esp. wet connectors or terminals) — 6. Check for blown or corroded fuses 7. Check alternator voltage (with engine speed at middle — or higher) After running for 8. Check operating sound of battery relay (when start several minutes: switch is turned ON or OFF) 27.5~ 29.5V —
Shop Manual - June 2013
Remedy
— — — — — — — — — —
AM E
1. Check for abnormal noise and smell 2. Check for oil leakage 3. Bleeding air
SA
Electrics, electrical equipment
1. Check for looseness, corrosion of battery terminal and wiring 2. Check for looseness, corrosion of alternator terminal and wiring 3. Check for looseness, corrosion of start motor terminal and wiring
TI N
Lubricating oil, coolant
1. Check fuel level and type of fuel 2. Check for impurities in fuel 3. Check hydraulic oil level 4. Check hydraulic oil strainer 5. Check swing drive oil level 6. Check engine oil level (in oil pan) 7. Check coolant level 8. Check dust indicator for clogging 9. Check hydraulic filter 10. Check final drive oil level
Hydraulic, mechanical Electrical equipment equipment 7-6
Criterion
RI C
Item
Tighten or replace Tighten or replace Repair Repair Bleed air Replace Add or replace Replace Repair Disconnect connector and dry Replace Replace Replace
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
5. Perform troubleshooting Conduct deep analysis and determine the cause of trouble according to the symptoms of the machine and the information displayed on the monitor.
A
Confirming that the third item above is normal, run startup check on the machine to determine the cause of failure. If the failure cannot be determined, turn off the engine and get more information from the operator.
● Failure codes may not indicate machine trouble. Temporary electrical failure can occur in controller memory, such as low battery output voltage, or open circuit in switch or sensor. Therefore, make repeated trials to erase the accumulated failure codes from the controller memory and confirm whether the failure codes are displayed after repeated trials. That is to say, "reoccurrence" of this trouble is possible. 6. Find out possible causes
RI C
4. Operate machine by yourself (trial run)
SA
NY
LA
TI N
● Never disconnect harness and hydraulic lines when the engine is running. Oil and water under high pressure and high temperature may squirt and cause personal injuries. Shut off then engine when disconnecting the harness and hydraulic lines.
AM E
Remark:
Before making a conclusion, check the most possible causes again and try to determine the root causes of troubles. Make a feasible repair scheme according to your conclusion.
Shop Manual - June 2013
7-7
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
7.3 Connector Location and Electrical Circuit Diagram Location Connector No.
Type
T-101
Terminal
1
Battery relay coil (positive)
M-2
D-1
T-102
Terminal
1
M-2
D-1
T-103
Terminal
1
M-2
D-1
T-104
Terminal
1
Battery relay coil (negative) Battery relay contact (output) Battery relay contact (input)
T-106
Terminal
1
Starting motor (B terminal)
J-6
T-107
Terminal
1
Alternator (B terminal)
K-6
T-108
Terminal
1
Preheating fuse (21#)
M-2
T-109
Terminal
1
Preheating fuse (17#)
T-110
Terminal
1
Body grounding
T-111
Terminal
1
T-112
Terminal
1
T-115
Terminal
1
T-119
Terminal
1
T-201
Terminal
1
Body grounding Preheating resistance wire terminal Starting motor grounding Body grounding (at the sides of battery) Body grounding
T-202
Terminal
1
Body grounding
X-6
K5
R
5
Horn relay
X-6
H-9
K6
R
5
Lamp relay
X-6
I-9
K8
R
5
Top lamp relay
X-6
J-9
K7
R
5
X-6
J-8
—
5
Battery relay
M-2
D-1
L-3
L-5
G-9 G-9
B-1
K-6 J-7
H-9
J-6
L-3
M-1
B-9
X-6
Parking relay
K3
NY
LA
M-2
M-1
Engine circuit
D-1
AM E
M-2
Cab circuit
R
5
Starting relay
X-6
L-4
KH
—
5
Preheating relay
Y-6
G-9
K10
R
5
Pilot valve relay
X-6
K-1
CN-106F
A
2
Junction connector
W-6
J-2
CN-142M
D
12
Intermediate connector
W-6
C-9
CN-131M
D
12
Intermediate connector
R-5
C-9
CN-302F
A
3
Intermediate connector
R-6
D-9
CN-301M
S
6
Intermediate connector
R-6
CN-132F
D
12
Intermediate connector
R-5
C-5
CN-1-110
D
6
Intermediate connector
AB-4
K-5
CN-121F
D
12
Intermediate connector
W-6
D-8
SA
KB
7-8
Shop Manual - June 2013
Sensor, solenoid circuit
A
Layout
RI C
Name of device
TI N
No. of pin
F-9
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
Location Connector No.
Type
No. of pin
CN-241M
D
12
CN-1-112
3
CN-1-111
Name of device
Intermediate connector
W-6
F-8
3
Intermediate connector
W-6
C-9
D
8
Intermediate connector
W-6
C-9
CN-7-705
D
12
Monitor panel
P-5
D-9
CN-801F
H
6
Intermediate connector
J-7
CN-445M
S
6
Intermediate connector
I-7
CN-204F
A
2
Intermediate connector
X-6
C-8
CN-412F
A
3
Intermediate connector
X-6
C-8
CN-112M
A
2
Washing motor
K-5
K-4
CN-102M
A
2
Platform lamp
CN-104M
A
2
Boom lamp (left)
CN-105M
A
2
CN-113M
A
2
CN-101M
S
CN-152M
Engine circuit
Sensor, solenoid circuit
A
Layout
Cab circuit
K-8
AM E
RI C
F-3
E-5
K-2
E-7
K-1
E-7
K-2
1
Boom lamp (right) Hydraulic oil temperature sensor Fuel level sensor
A
2
CN-613F
L
CN-661F
F-9
F-6
F-9
Intermediate connector
W-6
F-8
6
Safety relay
X-6
K-7
S
16
Intermediate connector
W-6
I-8
CN-161M
S
16
Intermediate connector
W-6
CN-115M
DF
3
Main pressure sensor (front)
I-7
F-4
CN-116M
DF
3
Main pressure sensor (rear)
I-7
F-4
CN-128M
DF
3
Arm-in pilot sensor
I-6
F-5
DF
3
Arm out pilot sensor
I-6
F-4
DF
3
Boom-up pilot sensor
I-6
F-5
DF
3
Boom-down pilot sensor
I-6
F-6
CN-124M
DF
3
Bucket-curl pilot sensor
I-6
F-6
CN-127M
DF
3
Bucket-dump pilot sensor
I-6
F-6
CN-123M
DF
3
Swing pilot sensor
I-6
CN-120M
DF
3
Travel pilot sensor (left)
I-6
F-7 F-7
CN-121M
DF
3
Travel pilot sensor (right)
I-6
F-8
CN-448M
S
2
Speed sensor
I-7
F-9
CN-307M
H
8
Top lamp switch
R-5
C-3
CN-303M
H
8
Work lamp switch
R-6
C-2
CN-305M
H
8
Washer switch
R-6
C-2
CN-126M
SA
CN-125M
LA
NY
CN-122M
TI N
I-7
Shop Manual - June 2013
7-9
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
Location Connector No.
Type
No. of pin
CN-304M
H
8
CN-104M
A
CN-306M
Name of device Layout
Cab circuit
Wiper switch
R-6
C-1
2
Horn switch
R-6
E-3
H
8
Preheating switch
R-5
CN-207F
S
12
Air conditioner unit
W-6
CN-113F
AMP
2
F. pump solenoid valve
I-7
CN-114F
AMP
2
I-7
CN-135F
AMP
2
CN-134F
AMP
2
CN-132F
AMP
2
CN-136F
AMP
2
CN-131F
AMP
2
CN-133F
AMP
2
R. pump solenoid valve Boom priority solenoid valve 2 Bucket Confluence solenoid valve Boom priority solenoid valve 1 Pilot solenoid valve Hi/Lo speed travel solenoid valve Swing priority solenoid valve
F-108
W
1
F-104
W
F-103
A
F-2
AM E
J-6
Sensor, solenoid circuit
F-1
RI C
J-6
Engine circuit
J-6
J-6
F-1 F-2 F-3 F-3
L-2 F-1
J-6
F-4
Coolant temperature sensor
J-7
F-8
1
Horn (right)
I-5
K-2
W
1
Horn (left)
I-5
K-2
CN-616F
AMP
81
Controller
W-6
A-4
CN-615F
AMP
40
Controller
W-6
A-9
CN-800M
S
2
Alternator terminal L/R
K-6
CN-7-707
AMP
2
Cigarette lighter
P-4
CN-150M
D
8
Intermediate connector
AE-3
HL
7
Radio
W-6
-
-
Fuse box
X-4
SA
PF021
LA
NY
CN-107M
TI N
J-6
CN-1-001M
A
2
Speaker (left)
AE-6
CN-1-002M
A
2
Speaker (right)
AD-7
CN-1-103M
A
2
Front right lamp
AB-6
CN-1-004M
A
2
Front left lamp
AC-5
CN-1-005
H
1
Cab lamp
AE-7
7-10
Shop Manual - June 2013
Description
S
SWP type, Yazaki
A/AMP
AMP, Japan
D
DT type, Japan
H
Hebi
HL
Hulane Connectors
L
Ling Xing Electronic Equipment
DF
Delphi, U.S.
W
AMP, Japan
Terminal
Round terminal
SA
NY
LA
TI N
AM E
RI C
Connector code
A
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
Shop Manual - June 2013
7-11
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
7.3.1 Connector location layout
CN-105M
CN-104M
CN-101M
RI C
A
8
AM E
7
TI N
6
CN-102M
LA
5
NY
4
2
SA
3
1 ZX215-1005033
A
7-12
B
C
D
Shop Manual - June 2013
E
F
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
CN-113M
CN-113F
CN-448M
F-108
T-112 CN-801F
CN-114F
T-106 CN-115M T-115
CN-116M
T-111
A
CN-445M
RI C
CN-800M T-107
AM E
CN-112M
F-104
CN-125M CN-126M
TI N
F-103
CN-124M
LA
CN-128M
CN-127M CN-123M
NY
CN-122M CN-121M CN-120M
SA
CN-131F CN-132F CN-133F CN-134F CN-135F
CN-136F
ZX215-1005034
G
H
I
J
K
Shop Manual - June 2013
L
M
7-13
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
CN-307M
CN-306M
CN-132F
CN-305M CN-304M CN-303M
9
CN-104M CN-302
8
A
CN-131M
RI C
CN-301M
AM E
7
CN-7-705
LA
5
TI N
6
4
NY
CN-7-707
SA
3
2
1 ZX215-1005035
N
7-14
O
P
Q
Shop Manual - June 2013
R
S
T
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
CN-661F
CN-161M
CN-1-111
CN-152M
CN-1-112
T-201
CN-241M
T-202
K5
CN-121F
K6 K10 K3
A
CN-142M
RI C
K7 K8 CN-613F
AM E
CN-615F CN-616F
TI N
KH
NY
LA
CN-412F
SA
CN-204F
PF021
CN-207F CN-107M CN-106F T
U
V
ZX215-1005036
W
X
Shop Manual - June 2013
Y
Z
7-15
Troubleshooting
SA
NY
LA
TI N
AM E
RI C
A
SY195/205/215/225C9 Crawler Hydraulic Excavator
7-16
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
CN-1-002M 9 CN-1-005 CN-1-001M
A
8
RI C
CN-1-103M
AM E
7
6
5
TI N
CN-1-004M
LA
4
2
SA
3
NY
CN-1-110
CN-150M
1 ZX215-1005037
AA
AB
AC
AD
Shop Manual - June 2013
AE
AF
7-17
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
7.3.2 Electrical element circuit diagram (cab circuit) PF021
CN-1-112 (D-3) 1
CANL
2
22
1
120ȍ resistance
2
CN-616F
CANH CANL 29 22
1 CN-1-111 (D-8)
2 3
24Vpower
4
9
5
1
1
2 3
2 3
0
50 1 5062 00 3
6 7 8
3
3
3
4 8 9 10 12
4 8 9 10 12
4 8 9 10 12
CN-142M (D-12)
50
1
506
2 3
00
9 10
Monitor
Ground
2 3 4
CN-131M CN-302F (D-12) (A-3) 50 50 1 1 1 1 506 506 2 2 2 2 00 3 3 00 3 3 4
5 6
5 6
1
12
CN-412F (A-3) CAN+ B
15
CAN-
16 17
8
0 43
18 19
1
1
2 3
2 3
1
1
2
2
GPS
21 22 23
4 5 9
10
10
11 12
11 12
26 27 28 29 30 31 32 33 34 35 36 38 39 40 41 42 43 44 45 46 47 48
6
F7
10A
28
F9
5A
29
F10
5A
42
F11
43
F14
49
F15
15A
70
F17
10A
20 A
10A
3 4 5 8 9 10 11 12 3 4 5 8 9 10 11 12
AM E
37
5A
26
1 CN-241M (D-12) 1
25
7
15A
F5
2
4 5 9
24
Fuel control knob voltage
F4
25
CN-121F (D-12) 2
CN-204F (A-2)
20
24
20
A
14
5A
RI C
13
20 A
21
11
AIN16
F1 F3
23
CN-7-705 (D-12)
Fuel ctrl dial
CANH
49 50 51 52 54 55 56
00 00 50
TI N
53
s GND s GND s PWR
CAN-
57 58 59
CAN+
60 61 62 64
1
65 66 67 68 69
s GND s PWR s PWR
73 74 75
00 50 50 CAN+ CAN-
76
4
CAN+ CAN-
2
3
3
4
4
5
5
12
71
77 78 79
1
2
LA
70 72
X-1
70
X-2
33 24 25
X-3 X-4 X-5
37
X-6
36
X-7
35 L 72
X-8 X-9
35 H
X-10
23
X-11
CN-132F (D-12)
63
5
28
12
80 81
X-12
CN-615F 83 84 85 86 87 88 89 90 91
SA
3
X-13
NY
82
X-14
23 Top lamp switch
92
20
93
Horn switch
94
95
70
31 21 CN-104M
72
96
97
CN-307M
98
99
TERMINAL B BRACCR1 R2 C HEAT
Work lamp switch
100
OFF ON START
101 102
2
103
24
33
104 CN-303M
105 106
Washer switch
107
22
108
Stabilized voltage diode
109 110
1
25
2
1
42
0
2
114 115
0
0
42
24Vpower supply 24Vpower supply
119 120
9
13
36 25
117
1
11
9
Wiper switch
0
116 118
11
CN-332M S-6
CN-305M
112 113
13
37
CN-153M
CN-152M
111
Ground Ground
Start switch
22 13
35 L 1
42 35 H
42
121
2
3 4 5
2
3 4 5
KB
Battery relay
CN-304M
122
1 1
2
+ -
-
+
Chassis GND
ZX215-1005038
A
7-18
B
C
D
Shop Manual - June 2013
E
F
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
★ This circuit diagram has been compiled by extracting the wiper system and each switch control system from the overall electrical circuit diagram. Access lamp
28 Horn relay
Lamp relay
Top lamp relay
9 K5
K6
K8
1
2
3 4 5
1
2
3 4 5
1
2
1
2
3 4 5
1
2
3 4 5
1
2
31
23
32
33
0
24
72
34
0
3 4 5 70
0
71
8
A
0
3 4 5
CN-1-110 (D-6) 1
1
2 36 3 35H 4
2 3 4
25
X-2
X-3 X-4
1 3 4 5 6 7 8
6 7 8
AM E
X-1 CN-161F (S-16) 1 3 4 5
35 L
X-5 X-6 X-7
TI N
X-10 X-11 X-12 X-13
CN-150M (S-8)
RL+ L0
0 26
1 2 3 4 5
6 7 8
6 7 8
R+ RL+
1 2
1
1 2
F-104 (W-1) CN-661F (S-12)
L0
3 4
71 0
3 4
1
32
0 71
Horn
CN-102M (A-2)
20 b
0
SA
34
38
1
1
2
2
1
1 2
2
1 2
2
CN-107M
Radio panel
1
2
CN-109M
57 61 a 60 a
3
Left boom work lamp
0
Right boom work lamp
0
2
34
Right speaker
1 Left speaker
4
0
5 6
38
0
7
26
38
Rotating stage work lamp
34
CN-102M (A-2) 1
0
34
CN-102M (A-2)
1 2 L+ 3 0 4 20 b 5 R6 L7
57
4
1
1
26
R+
0
5
0 71
F-103 (W-1)
34
20 b
Compressor clutch
M
37
1
F8
21
1 2
2
F6 21
0
1 2
Left top lamp
NY
71
1 2 3 4 5
6
Right top lamp
LA
X-14
7
CN-112M Washer motor (A-2) 1 2
X-9
M
5
5
X-8
R+
Wiper
RI C 0
8
CN-207F
Air conditioner panel
60a 61a
1
2
2
CN-7-111 (S-8)
CN-442F (S-12)
Cab lamp
0 1
4
4
7
7
8
8
8
8
26
1
60a 61a Ex air sensor
ZX215-1005039
G
H
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Shop Manual - June 2013
K
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7-19
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
7.3.3 Electrical control circuit diagram (engine circuit) CN-616F
6
5
4
Body ground
0
-
+ -
CN-241F (D-12)
20
+
1
42
22 10
1
2
2
9 21 11
9 11
20
13
F1 20 F2 21
20A22 5A10
CN-332M S-6 22 11 11 9
9
11 8
8
TERMINAL B BR ACCR1 R2 C HEAT OFF ON START
13 11
22 13 16
11
PF021
CN-152M CN-153M 1
0
2
42
1
2
42
0
A
506
X-1
RI C
21
AM E
7
22
T-110
00 00 50
TI N
8
1 Grounding 2 3 4 Controller power supply 5 6 7 8 9 10 11 12 13 14 Throttle position feedback 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 5Vpower supply 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 5Vpower supply74 5Vpower supply75 76 77 78 79 80 81
T-102
00 50 50
X-2
10 21
X-3
13
X-4
18
X-5
22
X-6
12
X-7
0
X-8
606
X-9
50
X-10 X-11
507
X-12
MT+
LA
9
T-119
X-13
00
X-14
MT-
CN-221M
F16
1 1
CN-615F
2
1
NY
CN-161F
12 12
27
105
14 14
Pilot switch
SA
3
82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99
100 101 102 103 104 Throttle motor output signal+ 105 106 107 108 109 110 111 112 113 Grounding 114 Grounding 115 116 117 118 24Vpower supply 119 24V power supply120 121 122
MT+
MT0 0
7
7
CN-331F 21
42 42
CN-241F
F11
21
T-102
4 1
2
0
T-101 T-103 T-104
1
2
3 4 5
1
2
3 4 5
1
2
3 4 5
1
2
3 4 5
KB Battery relay
Preheat switch
105 11 12 2
3 4 5
2
3 4 5
18
16 Pilot valve relay
1
K3 1
CN-306M
Locking relay
ZX215-1005040
A
7-20
B
C
D
Shop Manual - June 2013
E
F
G
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
★ This circuit diagram has been compiled by extracting the engine preheat system, startup system and governor system from the overall electrical circuit diagram. T-112
17 Preheat relay
Parking relay
KH
F13 160A T-108
T-109
1
2
3
4
5
1
2
3
4
5
0
18
16
K7
17
CN-661M (S-16)
15 15
1
2
3
4
5
1
2
3
4
5
0
13
9
64 63 65
Preheater
7 7 17 9 9 14 12 12
10
10
Preheater indicator
17
CN-442F (D-12)
1 1
0
X-2
10
CN-121F (D-12) 606
65
12
21
X-4
13
X-5
18
X-6
22
X-7
12
X-8
0
X-9
606 50 507
X-12
MT-
X-13
00
X-14
MT+
7
7
9
9
10
10
64 63
1 2 3 4 6
1 2 3 4 6
0
65
E Parking motor
0
7
CN-613F 12 a 14 10 47 0
1 2
1 2
3 4 6
3 4 6
12a 14 10 47
S L Safety relay R P
6
0
5 10 14 21 47
LA
X-11
6
P1
TI N
X-10
63
64
1
AM E
X-3
1 6
22
8
22 64 B 63 A 65 P2
CN-801F (H-6)
CN-661F (S-16)
5 5
A
21
RI C
X-1
2 2
R L B P
E 0
Generator Body ground
4
NY
CN-112M 1
2
12 a
CN-111F
12
1 1 2 2
12 12 a 21
E
SA
0
Starting motor
3
A3 Body ground
F-310
Charging indicator
10
1 1
14
2 2
F-311
Connector 282080-1 1
CN-316F (AMP-2)
2
0
1
1
2
2
606
2 Pilot solenoid valve
M13 (S-6) 50 507 MT00 MT+
1 2 3 5 6
1 2 3
1 2 Throttle motor 3 5 AC-2000 6
1
5 6
ZX215-1005041
G
H
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Shop Manual - June 2013
K
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M
7-21
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
7.3.4 Electrical control circuit diagram (sensor and solenoid valve circuit)
1 2 3 4 Controller power supply 5 6 7 8 9 10 Oil level sensor 11 12 13 14 15 16 17 18 Speed sensor GND 19 20 21 22 23 24 25 26 27 28 29 Coolant temp. sensor 30 Hydraulic oil temp. sensor 31 32 33 34 35 36 37 38 Pulse input 39 40 41 42 43 44 45 46 47 Oil pressure switch 48 Travel sensor (left) 49 Bucket dump sensor 50 Boom lower sensor 51 Arm out sensor 52 Rear pump main pressure sensor 53 s GND 54 s GND 55 s PWR 56 57 58 59 60 61 62 63 64 65 66 Travel sensor (right) 67 Swing sensor 68 Bucket curl sensor 69 Boom raise sensor 70 Arm in sensor 71 Front pump main pressure sensor 72 5V power supply GND 73 5Vpower supply GND 74 5Vpower supply GND 75 76 77 78 79 80 81
5
4
0 511
2
1
Engine speed sensor
1
1
2
2
Hydraulic oil temp. sensor
1
1
2
2
240欧 w1/4 F-108 (W-1)
Coolant temp. sensor
A
508 0
RI C
CN-121M (DF-3) A
50 0 201
B C CN-120M (DF-3) A A B B C C
A
B
C
A
Swing pilot pressure sensor
A
B
B
C
C
Bucket curl pilot pressure sensor
CN-127M (DF-3)
50 0 204
A
A
B
B
C
C
Bucket dump pilot pressure sensor
CN-125M (DF-3) A
A
B
B
C
C
Boom lower pilot pressure sensor
CN-126M (DF-3)
50 0 206
A
A
B
B
C
C
Boom raise pilot pressure sensor
CN-128M (DF-3)
50 0 203
A
A
B
B
C
C
Arm in pilot pressure sensor
CN-122M (DF-3)
50 0 202
A
A
B
B
C
C
Arm out pressure sensor
CN-115M (DF-3)
50 0 501
A
A
B
B
C
C
Front pump pressure sensor
CN-116M (DF-3)
50 0 502
NY
A
B
C
CN-124M (DF-3)
50 0 205
A
608 0
1
1
2
2
604 0
1
1
2
2
602 0
1
1
2
2
A
B
B
C
C
Rear pump pressure sensor
CN-133F (AMP-2)
Swing priority-A4 proportional solenoid valve
CN-134F (AMP-2)
Bucket confluent-A5 proportional solenoid valve
CN-132F (AMP-2)
Boom priority 1-A4 proportional solenoid valve
CN-135F (AMP-2)
603 0
1
1
2
2
Boom priority 2-A4 proportional solenoid valve
CN-113F (AMP-2)
702 0
607 0
Left travel pilot pressure sensor
CN-123M (DF-3)
50 0 207
24Vpower supply
Right travel pilot pressure sensor
B C
50 0 208
703 0
Oil pressure switch
A
50 0 200
SA
3
2
510
CN-615F Hi/Lo speed travel
82 83 84 85 86 87 Front pump solenoid proportional valve 88 Rear pump solenoid proportional valve 89 90 91 92 93 94 95 96 97 Swing priority solenoid valve 98 Bucket confluent valve 99 Boom priority 1 100 Boom priority 2 101 102 103 104 105 106 107 108 109 110 111 112 113 Grounding 114 Grounding 115 116 117 118 24Vpower supply 119 24Vpower supply 120 121 122
1
2
CN-152M (A-2)
AM E
6
511 42
TI N
7
1
CN-113M (A-2)
LA
8
Fuel level sensor
CN-448M (S-2)
108A 108B
Grounding
9
CN-101M (S-1) 1 1
509
CN-616F
1
1
2
2
Front pump proportional solenoid valve
CN-114F (AMP-2)
1
1
2
2
Rear pump proportional solenoid valve
CN-131F (AMP-2)
1
1
2
2
Hi/Lo speed travel solenoid valve
ZX215-1005042
A
7-22
B
C
D
Shop Manual - June 2013
E
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Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
7.3.5 SWP type connector Female (Socket)
RI C
A
Male (Plug)
7123-7414-40 (No.of pin: 1)
AM E
7222-7414-40
7123-1424-40 (No.of pin: 2)
LA
TI N
7222-1424-40
7123-7464-40 (No.of pin: 6)
SA
NY
7222-7464-40
7222-7484-40
7123-7484-40 (No.of pin: 8)
7222-7564-40
7123-7564-40 (No.of pin: 16)
Shop Manual - June 2013
7-23
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
7.3.6 A/AMP type connector
Female (Socket)
282104-1
282080-1 (No.of pin: 2)
AM E
RI C
A
Male (Plug)
282087-1 (No.of pin: 3)
174352-2 (No.of pin: 2)
SA
NY
174354-2
LA
TI N
282105-1
7-24
1473252-1
1473255-1 (No.of pin: 40)
1473244-1
1473247-1 (No.of pin: 81)
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
7.3.7 DT type connector
Shell (Plug)
Shell (Socket) B
B
A
A
A
DT06-2S
A
B
AM E
B
RI C
DT04-2P
C DT06-3S
C
DT04-3P (No.of pin: 3)
6
6
1
2
5
5
2
3
4
4
3
LA
TI N
1
DT06-6S
DT04-6P (No.of pin: 6) 8 5
5
SA
NY
8
A
4
1
4
1
DT04-8P (No.of pin: 8)
DT06-8S
12
7
7
12
1
6
6
1
DT04-12P (No.of pin: 12)
DT06-12S
Shop Manual - June 2013
7-25
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
7.4 Failure Symptoms and Troubleshooting Codes No.
Troubleshooting
Symptom
Code
E mode H mode (Engine)
Action to be taken concerning Service Code, User Code and Failure Code
6
Color of exhaust gas is too dark.(Incomplete combustion)
S-3
7
Engine pickup is poor.
S-4
8
Engine runs rough or is unstable.
9
Engine is short of output, or lacks power
3
4
RI C
2
A
5
Display User Code in monitor panel Display Service Code in electrical system after checking According to displayed failure history Display Failure Code in mechanical system after checking code failure history Engine-related failure Engine does not start up easily. (It always takes some time to start up the engine) Engine misfires.
E-1
AM E
1
E-2 E-4
S-2
S-5 H-2
S-6
H-5 S-7 S-8 S-9 S-10
16 Abnormal noises are heard
S-12 S-13
LA
13 Excessive fuel consumption Engine cooling water is mixed with engine oil, spurts out 14 or decreases 15 Engine oil amount increases. (Water or fuel gets in)
NY
TI N
10 Auto Idle fails. Excessive engine oil consumption, or color of exhaust gas 11 is blue 12 Premature engine oil contamination
S-1
S-11
17 Excessive vibrations are caused Failure related to work equipment, swing and travel
SA
18 Power supply of machine cannot be cut off.
E-3
19 There are abnormal noises from around hydraulic pump
H-4
20 All work equipment, travel and swing do not move
H-3
21 Speeds of all work equipment, travel and swing are slow When Machine Swings and Travels Simultaneously, 22 Travel Speed Lowers Largely Work equipment-related failure
H-1
23 All the equipment do not work
H-13
E-6
24 Cylinder do not work singly
H-9
25 Drift of cylinder is too large
H-10
26 Work equipment time lag is too big
H-11
7-26
Shop Manual - June 2013
S-6
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
No.
Troubleshooting
Symptom
Code
E mode H mode (Engine)
Other work equipment moves, when specific work equipment is relieved 28 Boom-up speed or power is low.
E-7
H-6
29 Arm speed or power is low.
E-8
H-7
30 Bucket speed or power is low.
E-9
H-8
27
H-12
E-10
32 Dual Speed Travel Not Functioning
E-13
H-15
RI C
31 Travel speed or power is low.
A
Travel-related failure
33 Machine tends to swerve while in travel
H-14
34 Machine is difficult to steer, or lacks power
H-16
H-17
36 Track shoe does not move (only on one side)
AM E
35 Travel speed cannot be shifted
H-18
Swing-related failure 37 Machine does not swing
H-19
38 Swing acceleration is poor, or swing speed is slow Upper structure overruns remarkably when stopping 39 swinging 40 Large shock is made when stopping swinging
H-20
H-22
41 Large sound is made when stopping swinging
H-23
42 Hydraulic drift of swing is large
H-24
LA
TI N
H-21
Monitor panel-related failure E-11
44 Monitor displays nothing.
E-12
45 Engine coolant temperature reading is incorrect.
E-14
NY
43 Monitor display is blank.
E-15
47 Arm-in pilot pressure reading is incorrect.
E-17
48 Arm-out pilot pressure reading is incorrect.
E-18
49 Boom-up pilot pressure reading is incorrect.
E-19
50 Boom-down pilot pressure reading is incorrect.
E-20
51 Bucket-close pilot pressure reading is incorrect.
E-21
52 Bucket-open pilot pressure reading is incorrect.
E-22
53 Swing pilot pressure reading is incorrect.
E-23
54 Left travel pilot pressure reading is incorrect.
E-24
55 Right travel pilot pressure reading is incorrect.
E-25
SA
46 Fuel level reading is incorrect.
Other failure 56 Preheating function fails.
E-5
57 Wiper does not work.
E-16 Shop Manual - June 2013
7-27
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
7.5 Troubleshooting with an Event Code
SA
NY
LA
TI N
AM E
RI C
A
Information in troubleshooting table .......................................................................................... 7-29 E111 (controller memory failure (FROM)) .................................................................................. 7-30 E212 (throttle motor current & motor connection abnormal) ..................................................... 7-31 E213 (throttle motor operation suspends) ................................................................................ 7-32 E214 (throttle motor working range abnormal) .......................................................................... 7-33 E015 (power supply voltage abnormal) ..................................................................................... 7-34 E116 (controller internal temperature abnormal) ....................................................................... 7-35 E017 (abnormal output of 5v power supply in sensor) .............................................................. 7-36 E118 (abnormal communication between controller and monitor) ............................................ 7-37 E320 (abnormality in front pump output pressure) .................................................................... 7-38 E321 (abnormality in rear pump output pressure) ..................................................................... 7-39 E322 (abnormality in arm-in pilot pressure)............................................................................... 7-40 E323 (abnormality in arm-out pilot pressure) ............................................................................ 7-41 E324 (abnormality in boom-raise pilot pressure) ...................................................................... 7-42 E325 (abnormality in boom-lower pilot pressure) ...................................................................... 7-43 E326 (abnormality in bucket-curl pilot pressure) ....................................................................... 7-44 E327 (abnormality in bucket-dump pilot pressure) .................................................................... 7-45 E328 (abnormality in swing pilot pressure ................................................................................. 7-46 E329 (abnormality in left travel pilot pressure) ......................................................................... 7-47 E330 (abnormality in right travel pilot pressure) ........................................................................ 7-48 E231 (abnormality in fuel control dial set voltage) ..................................................................... 7-49 E237 (abnormality in hydraulic oil temperature) ........................................................................ 7-50 E541 (abnormality in engine speed) .......................................................................................... 7-51 E450 (abnormality (a) in front pump proportional solenoid coil current) .................................... 7-52 E450 (abnormality (b) in front pump proportional solenoid coil current) .................................... 7-53 E451 (abnormality (a) in rear pump proportional solenoid coil current)..................................... 7-54 E451 (abnormality (B) in rear pump proportional solenoid coil current) .................................... 7-55 E452 (abnormality (A) in swing priority proportional solenoid coil current)................................ 7-56 E452 (abnormality (B) in swing priority proportional solenoid coil current)................................ 7-57 E453 (abnormality (A) in bucket confluence proportional solenoid coil current) ....................... 7-58 E453 (abnormality (B) in bucket confluence proportional solenoid coil current) ....................... 7-59 E455 (abnormality (A) in boom priority 2 proportional solenoid coil current) ............................. 7-60 E455 (abnormality (B) in boom priority 2 proportional solenoid coil current) ............................. 7-61 E460 (abnormality in dual speed travel solenoid valve) ............................................................ 7-62
7-28
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
Information in troubleshooting table User Code
Service Code
Display on monitor
—
Trouble
Title of failure shown in failure history
A
Failure is described on the monitor display. When failure is detected, the controller has taken action to protect the affected Response from controller system or equipment. Symptom of machine Symptom that is shown on the machine due to action of controller.
Standard value in normal state and remarks on troubleshooting
RI C
Cause 1 2
4
5
Possible causes of trouble (Given numbers are reference numbers, which do not indicate priority)
● Standard value under normal condition can be used to judge possible causes ● Reference for passing the above "Good" or "No Good" judgement ● Open circuit Faulty contact with connector or open circuit in wiring harness
TI N
3
AM E
● Faulty grounding An ungrounded wiring is grounded.
LA
Possible causes and standard value in normal state
Failure description
● Short circuit A wiring has mistaken contact with a 24 V electric circuit.
NY
Related circuit diagram
SA
This is part of the circuit diagram which shows the portion where the failure occurred. ● Connector No.: A connector number Indicates a connector. ● Arrow: An arrow roughly indicates the installing location.
Shop Manual - June 2013
7-29
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E111 (controller memory failure (FROM)) User Code
Service Code
Trouble Controller memory fails and the system slows down. E111 When the power is on, abnormality is detected by checking through FROM sumFailure description mation and RAM verification. Response from controller Stop the operation of motor and solenoid coil. 11
A
Engine acceleration fails and the machine acts slowly. .
RI C
1
Cause Standard value in normal state/Remarks on troubleshooting Internal failure No troubleshooting can be done for failure occurs in the inner of controller. (If of controller this failure occurs, replace the controller.)
AM E
2 3 4
TI N
5
SA
NY
LA
Possible causes and standard value in normal state
Symptom of machine
7-30
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E212 (throttle motor current & motor connection abnormal) User Code
Service Code
12
Trouble
Throttle motor loading circuit is abnormal and the engine acceleration fails.
E212 When the power is on, magnitude of throttle motor coil current is out of the Failure description range of 0.1A~1.8A and lasts for 2 seconds. Response from controller The controller stops the motor driving system when this failure is detected. Engine acceleration fails and the machine acts slowly.
A
Symptom of machine
4
Internal failure of controller
LA
3
Short circuit of harness (grounded)
RI C
Open circuit of harness
● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-445M ③ and ⑥ Resistance 12.2 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Unplug the controller and measure the resistance Resistance 12.2 Ω between pin 113 and pin 105. ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Unplug the connector CN-445M and measure the Resistance ≥2M Ω resistance between motor ③ ( ⑥ ) and the housing. No troubleshooting can be done for failure occurs in the inner of controller. (Except for the above reasons, the controller must be replaced in case of failure.)
AM E
2
Failure of throttle motor coil
TI N
1
Standard value in normal state/Remarks on troubleshooting
5
NY
Possible causes and standard value in normal state
Cause
CONTROLLER
75
THRTL FEEDBACK VOLT.
55
MT-
113
SA
SENSOR 5V
GND WIRE MT+
THROTTLE MOTOR
CN-445M 50# 507# MT-
55
0#
105
MT+
GREEN
1
1
2
2
3
3
4
4
5
5
YELLOW
6
6
BLUE
WHITE RED
M
CHASSIS HARNESS
CAB
ZX215-1005071
Shop Manual - June 2013
7-31
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E213 (throttle motor operation suspends) User Code
Service Code
13
Trouble
Operation of throttle motor suspends and engine acceleration fails.
E213 The controller monitoring accuracy deviates by over 5%, which is normally Failure description between 0.8 - 4.2 Voltage, after the system is powered on for 30 seconds. Response from controller The controller stops the motor driving system when this failure is detected. Engine acceleration fails and the machine acts slowly.
A
Symptom of machine
3
4
5
RI C
NY
6
AM E
2
TI N
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of throttle form troubleshooting. motor coil Resistance 12.2 Ω Between CN-445M ③ and ⑥ ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of 5V perform troubleshooting. power supply Between CN-445M ① and ⑤ Voltage About 5V ● Turn engine start switch to OFF position. Keep it at OFF position to perOpen circuit of form troubleshooting. Unplug the controller and measure the resistance harness Resistance 12.2 Ω between pin 113 and pin 105. ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of throttle perform troubleshooting. position sensor Between CN-445M ② and ground Voltage 0.8V~3.5V ● Turn engine start switch to OFF position. Keep it at OFF position to perShort circuit form troubleshooting. of harness Unplug the connector CN-445M and measure the Resistance ≥2M Ω (grounded) resistance between motor ③ ( ⑥ ) and the housing. No troubleshooting can be done for failure occurs in the inner of controller. Internal failure of (Except for the above reasons, the controller must be replaced in case of controller failure.)
LA
Possible causes and standard value in normal state
Cause
SA
CONTROLLER SENSOR 5V
50# 75
THRTL FEEDBACK VOLT.
55
MT-
113
GND WIRE MT+
THROTTLE MOTOR
CN-445M 507# MT-
55
0#
105
MT+
GREEN
1
1
2
2
3
3
4
4
5
5
YELLOW
6
6
BLUE
WHITE RED
M
CHASSIS HARNESS
CAB
ZX215-1005071
7-32
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E214 (throttle motor working range abnormal) User Code
Service Code
14
Trouble
Throttle motor working range is abnormal and the engine returns to auto idle.
E214 The voltage is below 0.8V at the minimal stroke or above 4.2V at the maximal Failure description stroke, and it lasts for 100msec when the power is on. Response from controller Turn the throttle to idle speed. Engine returns to auto idle.
A
Symptom of machine
3
4
5
RI C
SA
NY
6
AM E
2
TI N
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of throtform troubleshooting. tle motor coil Resistance 12.2 Ω Between CN-445M ③ and ⑥ ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of 5V perform troubleshooting. power supply Between CN-445M ① and ⑤ Voltage About 5V ● Turn engine start switch to OFF position. Keep it at OFF position to perOpen circuit of form troubleshooting. Unplug the controller and measure the resistance harness Resistance 12.2 Ω between pin 113 and pin 105. ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of perform troubleshooting. throttle position Between CN-445M ② and ground Voltage 0.8V—3.5V sensor ● Turn engine start switch to OFF position. Keep it at OFF position to perShort circuit form troubleshooting. Unplug the connector CN-445M and measure the of harness ≥2M Ω resistance between motor ③ ( ⑥ ) and the hous- Resistance (grounded) ing. No troubleshooting can be done for failure occurs in the inner of controller. Internal failure (Except for the above reasons, the controller must be replaced in case of of controller failure.)
LA
Possible causes and standard value in normal state
Cause
CONTROLLER SENSOR 5V
75
THRTL FEEDBACK VOLT.
55
MT-
113
GND WIRE MT+
THROTTLE MOTOR
CN-445M 50# 507# MT-
55
0#
105
MT+
GREEN
1
1
2
2
3
3
4
4
5
5
YELLOW
6
6
BLUE
WHITE RED
M
CHASSIS HARNESS
CAB
ZX215-1005071
Shop Manual - June 2013
7-33
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E015 (power supply voltage abnormal) User Code
Service Code
15
E015
Failure description
Trouble Power supply voltage is abnormal.
Voltage of power supply is above 36V when the machine is running.
Response from controller The system stops the motor and solenoid valve automatically. Symptom of machine
Engine acceleration fails and the machine acts slowly.
AM E
RI C
A
Possible causes and standard value in normal state
Cause Standard value in normal state/Remarks on troubleshooting Failure of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. 1 power supVoltage ≤25V Measure battery voltage ply ● Turn engine start switch to OFF position. And Then, keep the engine running Alternator to perform troubleshooting. 2 Measure the voltage between the alternator terminal abnormal Voltage About 28V B and ground. 3
CN-613 1 2 3 4 5 6
LA
START SWITCH TERMINAL B BR ACC R1 R2 C
TI N
4
HEAT OFF ON
CN-800M
1
-
+
L
S
R P
E
F-107
2
SA
NY
START
SAFETY RELAY
G R
-
L
P
B
E
ALTERNATOR
+ BATTERY RELAY
0
0 CHASSIS HARNESS
CAB
ZX215-1005072
7-34
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E116 (controller internal temperature abnormal) User Code
Service Code
16
Trouble
Internal temperature of controller is abnormal. Engine acceleration fails and the machine acts slowly.
E116 Internal temperature of controller keeps above 80°C or below -30°C for 10 secFailure description onds when the power is on. Response from controller The controller stops the motor and the solenoid coil.
A
Engine acceleration fails and the machine acts slowly.
RI C
Cause Standard value in normal state/Remarks on troubleshooting Internal No troubleshooting can be done for failure occurs in the inner of controller. (If this 1 failure of failure occurs, replace the controller.) controller
AM E
2 3
TI N
4 5
SA
NY
LA
Possible causes and standard value in normal state
Symptom of machine
Shop Manual - June 2013
7-35
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E017 (abnormal output of 5v power supply in sensor) User Code
Service Code
Trouble Abnormal output of power supply in sensor E017 The controller detects out over current or short circuit of sensor power source Failure description output when the power is on. Response from controller Only output alarm is enabled. 17
A
—
2
AM E
1
Standard value in normal state/Remarks on troubleshooting Short circuit ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. in harness Measure the resistance between pin 56, pin 75, pin 74 of Resistance ≥2M Ω (grounded) controller KC-MB and the ground. Internal No troubleshooting can be done for failure occurs in the inner of controller. (Except failure of for the above reasons, the controller must be replaced in case of failure.) controller
RI C
Cause
3
TI N
4 5
SA
NY
LA
Possible causes and standard value in normal state
Symptom of machine
7-36
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E118 (abnormal communication between controller and monitor) User Code
Service Code
18
Abnormal communication between controller and monitor
Trouble
E118 Communication of monitor is interrupted for 5 consecutive times when the Failure description power is on. Response from controller Only output alarm is enabled.
A
—
3
AM E
2
TI N
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of CAN form troubleshooting. resistance Resistance 60 Ω Between CN-7-709 ① and ② ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Unplug the controller and measure the resistance ≤1 Ω between pin 60 and CN-7-705 ③ harness Resistance Unplug the controller and measure the resistance ≤1 Ω between pin 78 and CN-7-705 ④ No troubleshooting can be done for failure occurs in the inner of controller. Internal failure (Except for the above reasons, the controller must be replaced in case of of controller failure.)
RI C
Cause
4
LA
Possible causes and standard value in normal state
Symptom of machine
CANH
120ȍ RESISTANCE
2 2
NY
CANH CANL
SA
60 78
CN-1-111 CN-441 3 3
1 2 3
1 2 3
29 22 0
CN-7-705 3 3 4 4 8 8 9 9 10 10 12 12
1 1
22
29
3 4 8 9 10 12
F1
MONITOR
CANL
1 1
CANL
CONTROLLER
CANH
CN-7-709
20A
F10 5A 21 PWR
CAB
20 PWR
CHASSIS HARNESS
ZX215-1005073
Shop Manual - June 2013
7-37
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E320 (abnormality in front pump output pressure) User Code
Service Code
20
Trouble
Front pump output pressure is abnormal. Only output alarm is enabled. .
E320 A pressure feedback voltage other than 0.25~4.75V keeps more than 200msec Failure description when the power is on. Response from controller Only output alarm is enabled.
A
—
3
4
Voltage
About 5V
● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of ≤1 Ω signal wire Between CN-115M C and pin 72 of controller Resistance Between CN-115M B and ground ≤1 Ω Short circuit ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. of signal wire Between CN-115M C and ground Resistance ≥2M Ω (grounded) ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of senperform troubleshooting. sor Between CN-115M C and ground Voltage 0.5±0.2V
AM E
2
Failure of 5V power supply Between CN-115M A and B
TI N
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting.
RI C
Cause
5
LA
Possible causes and standard value in normal state
Symptom of machine
NY
CONTROLLER
SA
FRONT PUMP PRESSUSRE SIGNAL COLLECTING PORT
72
GND WIRE
54
5V PWR SUPPLY
56
CN-446M 501# 00# 50#
FRONT PUMP PRESS. SENSOR
C
SIGNAL
B
GND WIRE
A
5V
CHASSIS HARNESS
CAB
ZX215-1005074
7-38
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E321 (abnormality in rear pump output pressure) User Code
Service Code
21
Trouble
Reading of rear pump output pressure is abnormal. Only output alarm is enabled. .
E321 A pressure feedback voltage other than 0.25~4.75V keeps more than 200msec Failure description when the power is on. Response from controller Only output alarm is enabled.
A
—
● 2
3
4
Open circuit of signal wire Short circuit ● of signal wire (grounded) ● Failure of sensor
5
RI C
●
AM E
1
Failure of 5V power supply
Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-116M A and B Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-116M C and pin 53 of controller ≤1 Ω Resistance Between CN-116M B and ground ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-116M C and ground Resistance ≥2M Ω Turn engine start switch to OFF position. Then, keep it at OFF position to perform troubleshooting. Between CN-116M C and ground Voltage 0.5±0.2V
TI N
Cause
LA
Possible causes and standard value in normal state
Symptom of machine
CN-447M
NY
CONTROLLER REAR PUMP PRESSURE SIGNAL COLLECT PORT
53
54
5V PWR SUPPLY
56
SA GND WIRE
502# 00# 50#
REAR PUMP PRESS. SENSOR
C
SIGNAL
B
GND WIRE
A
5V
CHASSIS HARNESS
CAB
ZX215-1005075
Shop Manual - June 2013
7-39
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E322 (abnormality in arm-in pilot pressure) User Code
Service Code
22
Trouble
Arm-in pilot pressure is abnormal. Only output alarm is enabled. .
E322 A pressure feedback voltage other than 0.25~4.75V keeps more than 200msec Failure description when the power is on. Response from controller Only output alarm is enabled.
A
The arm in motion is slow.
● 2
3
4
Open circuit of signal wire Short circuit ● of signal wire (grounded) ● Failure of sensor
RI C
●
AM E
1
Failure of 5V power supply
Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-128M A and B Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-128M C and pin 71 of controller ≤1 Ω Resistance Between CN-128M B and ground ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-128M C and ground Resistance ≥2M Ω Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-128M C and ground Voltage 0.5±0.2V
TI N
Cause
5
LA
Possible causes and standard value in normal state
Symptom of machine
CONTROLLER
NY
CN-428M
ARM-IN PILOT PRESSURE SIGNAL COLLECTING PORT
71
54
5V PWR SUPPLY
56
SA
GND WIRE
203# 00# 50#
ARM-IN PILOT PRESS. SENSOR
C
SIGNAL
B
GND WIRE
5V
A
CHASSIS HARNESS
CAB
ZX215-1005076
7-40
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E323 (abnormality in arm-out pilot pressure) User Code
Service Code
23
Trouble
Reading of arm-out pilot pressure is abnormal. Only output alarm is enabled.
E323 A pressure feedback voltage other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on. Response from controller Only output alarm is enabled.
A
Arm-out motion is slow.
2
Failure of 5V power supply Open circuit of signal wire
RI C
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-122M A and B Voltage About 5V ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-122M C and pin 52 of controller ≤1 Ω Resistance Between CN-122M B and ground ≤1 Ω
AM E
Cause
TI N
Short circuit ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. 3 of signal wire Between CN-122M C and ground Resistance ≥2M Ω (grounded) ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of senperform troubleshooting. 4 sor Between CN-122M C and ground Voltage 0.5±0.2V 5
LA
Possible causes and standard value in normal state
Symptom of machine
NY
CONTROLLER ARM-OUT PILOT PRESSURE SIGNAL COLLECTING PORT
52
54
5V PWR SUPPLY
56
SA GND WIRE
CN-122M 202# 00# 50#
ARM-OUT PILOT PRESS. SENSOR
C
SIGNAL
B
GND WIRE 5V
A
CHASSIS HARNESS
CAB
ZX215-1005077
Shop Manual - June 2013
7-41
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E324 (abnormality in boom-raise pilot pressure) User Code
Service Code
24
Trouble
Reading of boom-raise pilot pressure is abnormal. Only output alarm is enabled. .
E324 A pressure feedback voltage other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on. Response from controller Only output alarm is enabled.
A
Boom-raise motion is slow.
● 2
3
4
Open circuit of signal wire Short circuit ● of signal wire (grounded) ● Failure of sensor
RI C
●
AM E
1
Failure of 5V power supply
Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-126M A and B Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-126M C and 70 pin of controller ≤1 Ω Resistance Between CN-126M B and ground ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-126M C and ground Resistance ≥2M Ω Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-126M C and ground Voltage 0.5±0.2V
TI N
Cause
5
LA
Possible causes and standard value in normal state
Symptom of machine
CONTROLLER
NY
CN-126M
BOOM-RAISE PILOT PRESS. SIGNAL COLLECTING PORT
SA
GND WIRE
70
5V PWR SUPPLY
206# 00#
54 56
50#
BOOM-RAISE PILOT PRESS. SENSOR
C
SIGNAL
B
GND WIRE 5V
A
CAB
CHASSIS HARNESS
ZX215-1005078
7-42
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E325 (abnormality in boom-lower pilot pressure) User Code
Service Code
25
Trouble
Reading of boom-lower pilot pressure is abnormal. Only output alarm is enabled. .
E325 A pressure feedback voltage other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on. Response from controller Only output alarm is enabled.
A
Boom-lower motion is slow.
2
3
4
Open circuit of signal wire Short circuit ● of signal wire (grounded) ● Failure of sensor
5
RI C
●
AM E
1
●
Failure of 5V power supply
Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-125M A and B Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-125M C and pin 51 of controller ≤1 Ω Resistance Between CN-125M B and ground ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-125M C and ground Resistance ≥2M Ω Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-125M C and ground Voltage 0.5±0.2V
TI N
Cause
LA
Possible causes and standard value in normal state
Symptom of machine
CONTROLLER
NY
CN-125M
BOOM-LOWER PILOT PRESS SIGNAL COLLECTING PORT
SA
GND WIRE
5V PWR SUPPLY
51
207# 00#
54 56
50#
BOOM-LOWER PILOT PRESSURE SENSOR
C
SIGNAL
B
GND WIRE 5V
A
CAB
CHASSIS HARNESS
ZX215-1005079
Shop Manual - June 2013
7-43
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E326 (abnormality in bucket-curl pilot pressure) User Code
Service Code
26
Trouble
Reading of bucket-curl pilot pressure is abnormal. Only output alarm is enabled. .
E326 A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200msec Failure description when the power is on. Response from controller Only output alarm is enabled.
A
Bucket-curl motion is low.
● 2
Open circuit of signal wire
Short circuit ● 3 of signal wire (grounded) ● Failure of sen4 sor
RI C
●
AM E
1
Failure of 5V power supply
Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-124M A and B Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-124M C and 69 pin of controller ≤1 Ω Resistance Between CN-124M B and ground ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-124M C and ground Resistance ≥2M Ω Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-124M C and ground Voltage 0.5±0.2V
TI N
Cause
5
LA
Possible causes and standard value in normal state
Symptom of machine
CONTROLLER
NY
CN-124M 69
GND WIRE
54
SA
BUCKET-DIG PILOT PRESS. SIGNAL COLLECTING PORT
5V PWR SUPPLY
56
205# 00# 50#
BUCKET-DIG PILOT PRESSURE SENSOR
C
SIGNAL
B
GND WIRE 5V
A
CAB
CHASSIS HARNESS
ZX215-1005080
7-44
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E327 (abnormality in bucket-dump pilot pressure) User Code
Service Code
27
Trouble
Reading of Bucket-dump pilot pressure is abnormal. Only output alarm is enabled. .
E327 A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200msec Failure description when the power is on. Response from controller Only output alarm is enabled.
A
Bucket-dump motion is low
2
Open circuit of signal wire
Short circuit ● 3 of signal wire (grounded) ● Failure of sen4 sor 5
RI C
●
AM E
1
●
Failure of 5V power supply
Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-128M A and B Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-128M C and pin 50 of controller ≤1 Ω Resistance Between CN-128M B and ground ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-128M C and ground Resistance ≥2M Ω Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-128M C and ground Voltage 0.5±0.2V
TI N
Cause
LA
Possible causes and standard value in normal state
Symptom of machine
CONTROLLER
NY
CN-128M 50
GND WIRE
54
5V PWR SUPPLY
56
SA
BUCKET-DUMP PILOT PRESS. SIGNAL COLLECTING PORT
204# 00# 50#
BUCKET-DUMP PILOT PRESSURE SENSOR
C
SIGNAL
B
GND WIRE 5V
A
CHASSIS HARNESS
CAB
ZX215-1005081
Shop Manual - June 2013
7-45
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E328 (abnormality in swing pilot pressure User Code
Service Code
28
Trouble
Reading of swing pilot pressure is abnormal. Only output alarm is enabled. .
E328 A pressure feedback voltage other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on. Response from controller Only output alarm is enabled.
A
Swinging motion is slow.
● 2
Open circuit of signal wire
Short circuit ● 3 of signal wire (grounded) ● Failure of sen4 sor
RI C
●
AM E
1
Failure of 5V power supply
Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-123M A and B Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-123M C and pin 68 of controller ≤1 Ω Resistance Between CN-123M B and ground ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-123M C and ground Resistance ≥2M Ω Turn engine start switch to OFF position. Then, keep it at OFF position to perform troubleshooting. Between CN-123M C and ground Voltage 0.5±0.2V
TI N
Cause
5
LA
Possible causes and standard value in normal state
Symptom of machine
CONTROLLER
NY
CN-123M
SWING PILOT PRESSURE SIGNAL COLLECTING PORT
SA
GND WIRE
68
5V PWR SUPPLY
208# 00#
54 56
50#
SWING PILOT PRESS. SENSOR
C
SIGNAL
B
GND WIRE 5V
A
CAB
CHASSIS HARNESS
ZX215-1005082
7-46
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E329 (abnormality in left travel pilot pressure) User Code
Service Code
29
Trouble
Reading of left travel pilot pressure is abnormal. Only output alarm is enabled. .
E329 A pressure feedback voltage other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on. Response from controller Only output alarm is enabled.
A
Left travel speed is low. Travel deviates.
● 2
Open circuit of signal wire
Short circuit ● 3 of signal wire (grounded) ● Failure of sen4 sor 5
RI C
●
AM E
1
Failure of 5V power supply
Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-120M A and B Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-120M C and pin 49 of controller ≤1 Ω Resistance Between CN-120M B and ground ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-120M C and ground Resistance ≥2M Ω Turn engine start switch to OFF position. Then, keep it at OFF position to perform troubleshooting. Between CN-120M C and ground Voltage 0.5±0.2V
TI N
Cause
LA
Possible causes and standard value in normal state
Symptom of machine
NY
CONTROLLER
SA
L. TRAVEL PILOT PRESSURE SIGNAL COLLECTING PORT
49
GND WIRE
54
5V PWR SUPPLY
56
CAB
CN-120M 200# 00# 50#
L. TRAVEL PILOT PRESS. SENSOR
C
SIGNAL
B
GND WIRE
5V
A
CHASSIS HARNESS
ZX215-1005083
Shop Manual - June 2013
7-47
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E330 (abnormality in right travel pilot pressure) User Code
Service Code
30
Trouble
Reading of right travel pilot pressure is abnormal. Only output alarm is enabled. .
E330 A pressure feedback voltage other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on. Response from controller Only output alarm is enabled.
A
Right travel speed is low. Travel deviates.
● 2
Open circuit of signal wire
Short circuit ● 3 of signal wire (grounded) ● Failure of sen4 sor
RI C
●
AM E
1
Failure of 5V power supply
Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-121M A and B Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-121M C and pin 67 of controller ≤1 Ω Resistance Between CN-121M B and ground ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-121M C and ground Resistance ≥2M Ω Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-121M C and ground Voltage 0.5±0.2V
TI N
Cause
5
LA
Possible causes and standard value in normal state
Symptom of machine
CONTROLLER
NY
CN-121M 67
R. TRAVEL PILOT PRESSURE SIGNAL COLLECTING PORT
SA
GND WIRE
5V PWR SUPPLY
201# 00#
54 56
50#
R. TRAVEL PILOT PRESS. SENSOR
C
SIGNAL
B
GND WIRE
A
5V
CHASSIS HARNESS
CAB
ZX215-1005084
7-48
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E231 (abnormality in fuel control dial set voltage) User Code
Service Code
31
Trouble
Voltage setting of fuel control dial is abnormal. Engine returns to auto idle.
E231 The voltage of fuel control dial other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on. Response from controller The throttle is switched to idle position.
A
Engine returns to auto idle speed.
3
4
Short circuit ● of signal wire (grounded) Short circuit ● of signal wire (contact with Between CN-302F ② and ground Voltage ≤5V power supply) ● Turn engine start switch to OFF position. Keep it at OFF position to perDefective form troubleshooting. Unplug the connector CN-302F, and measure the knob Resistance 5K±15% Ω resistance between dial ① and ③
LA
5
●
Open circuit of signal wire
AM E
2
TI N
1
●
Failure of 5V power supply
Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-302F ① and ③ Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-302F ② and pin 34 of controller Resistance ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-302F ② and ground Resistance ≥2M Ω Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting.
RI C
Cause
NY
Possible causes and standard value in normal state
Symptom of machine
SA
SENSOR 5V
75
GND WIRE
55
FUEL CONTROL DIAL SET VOLTAGE
34
CN-142M
CN-131M
1
1
2
2
3
3
CN-302F 50# 506# 0#
1
1
2
2
3
3
YELLOW BLUE
FUEL CTRL DIAL
RED
CAB
ZX215-1005085
Shop Manual - June 2013
7-49
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E237 (abnormality in hydraulic oil temperature) User Code
Service Code
Hydraulic oil temperature is abnormal. Only output alarm is enabled.
E237 A voltage other than 0.2 – 4.75V, transformed from hydraulic oil temperature Failure description that is detected by controller, keeps more than 200msec. Only output alarm is enabled. The alarm resets automatically when conditions Response from controller become normal. Symptom of machine —
2
Open circuit of wire harness
3
Short circuit of wire harness (grounded)
4
Failure of 24V power supply
RI C
Failure of sensor
AM E
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at OFF position to perform troubleshooting. Between CN-113M ① and ground Voltage 0.2~4.75V ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-113M ① and pin 31 of controller Resistance ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-113M ① and ground Resistance ≥1M Ω ● Turn engine start switch to OFF position. Keep it at ON position to perform troubleshooting. Between CN-113M ② and ground Voltage About 24V
TI N
Cause
5
LA
Possible causes and standard value in normal state
A
37
Trouble
CN-152M 0#
NY
1
1 240
CONTROLLER
SA
2
2
CN-113M
HYDRAULIC OIL TEMP SENSOR
31
HYDRAULIC OIL TEMP SENSOR
1
1
SIGNAL
2
2
24V PWR SUPPLY
24VPWR SUPPLY
CHASSIS HARNESS
CAB
ZX215-1005086
7-50
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E541 (abnormality in engine speed) User Code
Service Code
41
E541
Trouble
Engine speed is abnormal. Only output alarm is enabled.
A
CPU detects out that engine speed is too low (below 100 rpm). Only output alarm is enabled. The alarm resets automatically when conditions Response from controller become normal. Symptom of machine —
2
Open circuit of wire harness
3
Short circuit of wire harness (grounded)
4
Failure of sensor
5
RI C
Normal condition
AM E
1
Standard value in normal state/Remarks on troubleshooting ● Code 41 will be displayed on the monitor when engine start switch is turned from the OFF position to the ON position. This is normal as the engine is not started. ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-448M ① and pin 38 of controller ≤1 Ω Resistance Between CN-448M ② and pin 19 of controller ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-448M ① and ground Resistance ≥1M Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Unplug the connector CN-448M, and measure the Resistance 2.3±0.2k Ω resistance between the speed sensors's ① and ② .
TI N
Cause
LA
Possible causes and standard value in normal state
Failure description
NY
CONTROLLER
SA
ENGINE SPEED PROBING
GND WIRE
CN-448M 38
19
108A
108B
CAB
ENGINE SPEED SENSOR
1
SIGNAL
2
GND WIRE
CHASSIS HARNESS
ZX215-1005087
Shop Manual - June 2013
7-51
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E450 (abnormality (a) in front pump proportional solenoid coil current) User Code
Service Code
50
Trouble
Front pump proportional solenoid coil current is abnormal. The system operates slowly.
E450 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 1.8A lasts for 1 second. Differential current occurs in drive protection loop. Response from controller Stop the solenoid coil when failure is detected. Power supply must be restored.
2
Short circuit of wire harness (grounded)
Failure of pro3 portional valve coil 4
Failure of controller
RI C
Open circuit of wire harness
AM E
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-113F ① and pin 88 of controller ≤1 Ω Resistance Between CN-113F ② and ground ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-113F ① and wire 0# Resistance ≥1M Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Unplug the connector CN-113F, and measure the Resistance 17.5 Ω resistance between solenoid valve's ① and ② No troubleshooting can be done for failure occurs in the inner of controller. (Except for the above reasons, the controller must be replaced in case of this failure.)
TI N
Cause
A
System operates slowly.
5
LA
Possible causes and standard value in normal state
Symptom of machine
NY
CONTROLLER
88
GND WIRE
55
SA
FRONT PUMP SOLENOID VALVE SIGNAL OUTPUT PORT
CN-113F 702#
0#
1
2
SOLENOID VALVE (FRONT PUMP)
SIGNAL
GND WIRE
CHASSIS HARNESS
CAB
ZX215-1005088
7-52
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E450 (abnormality (b) in front pump proportional solenoid coil current) User Code
Service Code
50
Trouble
Front pump proportional solenoid coil current is abnormal. The system operates slowly.
E450 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 0.1 A lasts for 1 second. Differential current occurs in drive protection loop. Response from controller Stop the solenoid coil when failure is detected. Power supply must be restored.
A
System operates slowly.
3
4
AM E
2
TI N
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-113F ① and pin 88 of controller ≤1 Ω wire harness Resistance Between CN-113F ② and ground ≤1 Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness Between CN-113F ① and wire 0# Resistance ≥1M Ω (grounded) Failure of pro- ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. portional valve Unplug the connector CN-113F, and measure the Resistance 17.5 Ω coil resistance between solenoid valve's ① and ② . No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of this troller failure.)
RI C
Cause
LA
5
NY
Possible causes and standard value in normal state
Symptom of machine
CONTROLLER
CN-113F 88
GND WIRE
55
SA
FRONT PUMP SOLENOID VALVE SIGNAL OUTPUT PORT
702#
0#
1
2
SOLENOID VALVE (FRONT PUMP)
SIGNAL
GND WIRE
CHASSIS HARNESS
CAB
ZX215-1005088
Shop Manual - June 2013
7-53
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E451 (abnormality (a) in rear pump proportional solenoid coil current) User Code
Service Code
51
Trouble
Rear pump proportional solenoid coil current is abnormal. The system operates slowly.
E451 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 1.8 A lasts for 1 second. Differential current occurs in drive protection loop. Response from controller Stop the solenoid coil when failure is detected. Power supply must be restored.
A
System operates slowly.
3
4
AM E
2
TI N
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-114F ① and pin 89 of controller ≤1 Ω wire harness Resistance Between CN-114F ② and ground ≤1 Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness Between CN-114F ① and wire 0# Resistance ≥1M Ω (grounded) ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of proform troubleshooting. portional valve Unplug the connector CN-114F, and measure the Resistance 17.5 Ω coil resistance between solenoid valve's ① and ② . No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of this troller failure.)
RI C
Cause
5
LA
Possible causes and standard value in normal state
Symptom of machine
NY
CONTROLLER
SA
REAR PUMP SOLENOID VALVE SIGNAL OUTPUT PORT
GND WIRE
702#
89
55
CAB
CN-114F
0#
1
2
SOLENOID VALVE (REAR PUMP) SIGNAL
GND WIRE
CHASSIS HARNESS
ZX215-1005089
7-54
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E451 (abnormality (B) in rear pump proportional solenoid coil current) User Code
Service Code
51
Trouble
Rear pump proportional solenoid coil current is abnormal. The system operates slowly.
E451 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 0.1 A lasts for 1 second. Differential current occurs in drive protection loop. Response from controller Stop the solenoid coil when failure is detected. Power supply must be restored.
A
System operates slowly.
3
4
AM E
2
TI N
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-114F ① and pin 89 of controller ≤1 Ω wire harness Resistance Between CN-114F ② and ground ≤1 Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness Between CN-114F ① and wire 0# Resistance ≥1M Ω (grounded) ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of proform troubleshooting. portional valve Unplug the connector CN-114F, and measure the Resistance 17.5 Ω coil resistance between solenoid valve's ① and ② No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of this troller failure.)
RI C
Cause
5
LA
Possible causes and standard value in normal state
Symptom of machine
NY
CONTROLLER
SA
REAR PUMP SOLENOID VALVE SIGNAL OUTPUT PORT
GND WIRE
CN-114F 702# 89
55
CAB
0#
1
2
SOLENOID VALVE (REAR PUMP) SIGNAL
GND WIRE
CHASSIS HARNESS
ZX215-1005089
Shop Manual - June 2013
7-55
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E452 (abnormality (A) in swing priority proportional solenoid coil current) User Code
Service Code
Current through the proportional solenoid coil for swing priority is abnormal.
E452 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 1.8A lasts for 1 second. Differential current occurs in drive protection loop. Operation of solenoid coil is stopped when failure is detected. Power supply Response from controller must be restored. Symptom of machine —
3
4
RI C
TI N
2
LA
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-133F ① and pin 98 of controller ≤1 Ω wire harness Resistance Between CN-133F ② and ground ≤1 Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness Between CN-133F ① and wire 0# Resistance ≥1M Ω (grounded) ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of proform troubleshooting. portional valve Unplug the connector CN-133F, and measure the Resistance 17.5 Ω coil resistance between solenoid valve's ① and ② No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of this troller failure.)
AM E
Cause
5
NY
Possible causes and standard value in normal state
A
52
Trouble
SA
CONTROLLER
98
GND WIRE
55
SWING PRIORITY SOLENOID VALVE SIGNAL OUTPUT PORT
CN-133F 608#
0#
CAB
SOLENOID VALVE (SWING PRIORITY)
1
SIGNAL
2
GND WIRE
CHASSIS HARNESS
ZX215-1005090
7-56
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E452 (abnormality (B) in swing priority proportional solenoid coil current) User Code
Service Code
Current through the proportional solenoid coil for swing priority is abnormal.
E452 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 0.1A lasts for 1 second. Differential current occurs in drive protection loop. Operation of solenoid coil is stopped when failure is detected. Power supply Response from controller must be restored. Symptom of machine —
3
4
RI C
TI N
2
LA
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-133F ① and pin 98 of controller ≤1 Ω wire harness Resistance Between CN-133F ② and ground ≤1 Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness Resistance ≥1M Ω Between CN-133F ① and wire 0# (grounded) ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of proform troubleshooting. portional valve Unplug the connector CN-133F, and measure the Resistance 17.5 Ω coil resistance between solenoid valve's ① and ② No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of this troller failure.)
AM E
Cause
5
NY
Possible causes and standard value in normal state
A
52
Trouble
CONTROLLER
SA
SWING PRIORITY SOLENOID VALVE SIGNAL OUTPUT PORT
GND WIRE
CN-133F 98
55
608#
0#
CAB
SOLENOID VALVE (SWING PRIORITY)
1
SIGNAL
2
GND WIRE
CHASSIS HARNESS
ZX215-1005090
Shop Manual - June 2013
7-57
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E453 (abnormality (A) in bucket confluence proportional solenoid coil current) User Code
Service Code
Current through the proportional solenoid coil for bucket confluence is abnormal. Motion of bucket is slow.
E453 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 1.8 A lasts for 1 second. Differential current occurs in drive protection loop. Operation of solenoid coil is stopped when failure is detected. Power supply Response from controller must be restored. Symptom of machine Motion of bucket is slow.
3
4
RI C
TI N
2
LA
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-134F ① and 99 pin of controller ≤1 Ω wire harness Resistance Between CN-134F ② and ground ≤1 Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness Between CN-134F ① and wire 0# Resistance ≥1M Ω (grounded) ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of proform troubleshooting. portional valve Unplug the connector CN-134F, and measure the Resistance 17.5 Ω coil resistance between solenoid valve's ① and ② No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of this troller failure.)
AM E
Cause
5
NY
Possible causes and standard value in normal state
A
53
Trouble
SA
CONTROLLER
BUCKET CONFLUENCE SOLENOID VALVE SIGNAL OUTPUT PORT
GND WIRE
99
55
CN-134F 604#
0#
CAB
SOLENOID VALVE (BUCKET CONFLU)
1
SIGNAL
2
GND WIRE
CHASSIS HARNESS
ZX215-1005091
7-58
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E453 (abnormality (B) in bucket confluence proportional solenoid coil current) User Code
Service Code
Current through the proportional solenoid coil for bucket confluence is abnormal. Motion of bucket is slow.
E453 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 0.1A lasts for 1 second. Differential current occurs in drive protection loop. Operation of solenoid coil is stopped when failure is detected. Power supply Response from controller must be restored. Symptom of machine Motion of bucket is slow.
3
4
RI C
TI N
2
LA
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-134F ① and pin 99 of controller ≤1 Ω wire harness Resistance Between CN-134F ② and ground ≤1 Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness Between CN-134F ① and wire 0# Resistance ≥1M Ω (grounded) ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of proform troubleshooting. portional valve Unplug the connector CN-134F, and measure the Resistance 17.5 Ω coil resistance between solenoid valve's ① and ② No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of this troller failure.)
AM E
Cause
5
NY
Possible causes and standard value in normal state
A
53
Trouble
SA
CONTROLLER
BUCKET CONFLUENCE SOLENOID VALVE SIGNAL OUTPUT PORT
GND WIRE
CN-134F 99
55
604#
0#
CAB
SOLENOID VALVE (BUCKET CONFLU)
1
SIGNAL
2
GND WIRE
CHASSIS HARNESS
ZX215-1005091
Shop Manual - June 2013
7-59
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E455 (abnormality (A) in boom priority 2 proportional solenoid coil current) User Code
Service Code
Current through the proportional solenoid coil for boom priority is abnormal.
E455 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 1.8 A lasts for 1 second. Differential current occurs in drive protection loop. Operation of solenoid coil is stopped when failure is detected. Power supply Response from controller must be restored. Symptom of machine —
3
4
RI C
TI N
2
LA
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-135F ① and pin 101 of controller ≤1 Ω wire harness Resistance Between CN-135F ② and ground ≤1 Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness Between CN-135F ① and wire 0# Resistance ≥1M Ω (grounded) ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of proform troubleshooting. portional valve Unplug the connector CN-135F, and measure the Resistance 17.5 Ω coil resistance between solenoid valve's ① and ② No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of this troller failure.)
AM E
Cause
5
NY
Possible causes and standard value in normal state
A
55
Trouble
CONTROLLER
SA
BOOM PRIORITY 2 SOLENOID VALVE SIGNAL OUTPUT PORT
GND WIRE
101
55
CN-135F 603#
0#
CAB
SOLENOID VALVE (BOOM PRIORITY 2 )
1
SIGNAL
2
GND WIRE
CHASSIS HARNESS
ZX215-1005093
7-60
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E455 (abnormality (B) in boom priority 2 proportional solenoid coil current) User Code
Service Code
Current through the proportional solenoid coil for boom priority is abnormal.
E455 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 0.1A lasts for 1 second. Differential current occurs in drive protection loop. Operation of solenoid coil is stopped when failure is detected. Power supply Response from controller must be restored. Symptom of machine —
3
4
RI C
TI N
2
LA
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-135F ① and pin 101 of controller ≤1 Ω wire harness Resistance Between CN-135F ② and ground ≤1 Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness Between CN-135F ① and wire 0# Resistance ≥1M Ω (grounded) ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of proform troubleshooting. portional valve Unplug the connector CN-135F, and measure the Resistance 17.5 Ω coil resistance between solenoid valve's ① and ② No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of this troller failure.)
AM E
Cause
5
NY
Possible causes and standard value in normal state
A
55
Trouble
CONTROLLER
SA
BOOM PRIORITY 2 SOLENOID VALVE SIGNAL OUTPUT PORT
GND WIRE
CN-135F
101
55
603#
0#
CAB
SOLENOID VALVE (BOOM PRIORITY 2 )
1
SIGNAL
2
GND WIRE
CHASSIS HARNESS
ZX215-1005093
Shop Manual - June 2013
7-61
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E460 (abnormality in dual speed travel solenoid valve) User Code
Service Code
60
E460
Failure description
Trouble
Connection of the solenoid coil for dual speed travel is abnormal. High speed travel is not functioning.
Abnormality, open circuit or short circuit occurs in the proportional solenoid coil.
Response from controller Only output alarm is enabled. High speed travel is not functioning.
3
4
RI C
AM E
2
TI N
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-132F ① and pin 100 of controller ≤1 Ω wire harness Resistance Between CN-132F ② and ground ≤1 Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness Between CN-132F ① and wire 0# Resistance ≥1M Ω (grounded) ● Turn engine start switch to OFF position. Keep it at OFF position to perFailure of proform troubleshooting. portional valve Unplug the connector CN-132F, and measure the Resistance 17.5 Ω coil resistance between solenoid valve's ① and ② No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of this troller failure.)
A
Cause
5
LA
Possible causes and standard value in normal state
Symptom of machine
NY
CONTROLLER
SA
DUAL SPEED TRAVEL SOLENOID VALVE SIGNAL OUTPUT PORT
GND WIRE
100
55
CN-132F 607#
0#
CAB
SOLENOID VALVE (DUAL-SPEED TRAVEL)
1
SIGNAL
2
GND WIRE
CHASSIS HARNESS
ZX215-1005094
7-62
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
7.6 Troubleshooting of Electrical System (E - Mode)
SA
NY
LA
TI N
AM E
RI C
A
Information in troubleshooting table .......................................................................................... 7-64 E-1 Engine does not start ......................................................................................................... 7-65 E-2 Engine runs rough or is unstable ....................................................................................... 7-67 E-3 Power supply of machine cannot be cut off ....................................................................... 7-68 E-4 Auto idle not functioning ..................................................................................................... 7-70 E-5 Preheating function fails..................................................................................................... 7-71 E-6 Work equipment does not work ......................................................................................... 7-72 E-7 Boom-raise speed or power is low ...................................................................................... 7-73 E-8 Arm speed or power is low ................................................................................................. 7-74 E-9 Bucket speed or power is low ............................................................................................ 7-75 E-10 Travel speed or power is low ........................................................................................... 7-77 E-11 Blank monitor display ....................................................................................................... 7-78 E-12 Monitor displays nothing .................................................................................................. 7-79 E-13 Dual speed travel not functioning..................................................................................... 7-80 E-14 Incorrect engine coolant reading...................................................................................... 7-81 E-15 Incorrect fuel level reading ................................................................................................ 7-82 E-16 Wiper does not work ........................................................................................................ 7-83 E-17 Incorrect arm-in pilot pressure reading ............................................................................ 7-84 E-18 Incorrect arm-out pilot pressure reading .......................................................................... 7-85 E-19 Incorrect boom-raise pilot pressure reading .................................................................... 7-86 E-20 Incorrect boom-lower pilot pressure reading.................................................................... 7-87 E-21 Incorrect bucket-curl pilot pressure reading ..................................................................... 7-88 E-22 Incorrect bucket-dump pilot pressure reading.................................................................. 7-89 E-23 Incorrect swing pilot pressure reading ............................................................................. 7-90 E-24 Incorrect left travel pilot pressure reading ........................................................................ 7-91 E-25 Incorrect right travel pilot pressure reading...................................................................... 7-92
Shop Manual - June 2013
7-63
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
Information in troubleshooting table ● The following information is contained in the troubleshooting table and related electric circuit diagrams. Fully understand these information before carrying out troubleshooting. Trouble
Trouble which occurs on the machine
Related information
Information related to detected trouble or troubleshooting
RI C
A
Standard value in normal state and remarks on troubleshooting
1 2
4
● Standard value in normal state, which is used to judge possible causes that might be OK or N/G. ● A reference value is used to determine OK or N/G.
LA
5
< Description >
TI N
Possible causes of trouble (Given numbers are reference numbers, which do not indicate priority)
AM E
3
NY
Possible causes and standard value in normal state
Cause
SA
Related circuit diagram
This is part of the circuit diagram which shows the portion where the failure occurred. ● Connector No.: A connector number Indicates a connector. ● Arrow: An arrow roughly indicates the installing location.
7-64
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-1 Engine does not start Trouble
Engine cannot be started.
Related information
5
RI C
AM E
4
ness
Wire 12# and start relay terminal SW
Resistance
≤1 Ω
NY
Start relay terminal L and safety relay terminal S ≤1 Ω Failure of 6 Battery terminal "+" (wire 20#) and control dial wire 22# Resistance ≤1 Ω fuse F1 Short cir- ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. cuit of wire 7 Start relay terminal SW and ground ≥1 M Ω harness Resistance Engine input terminal S and ground ≥1 M Ω (grounded) Internal ● Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. 8 failure of Alternator terminal P and ground Voltage ≤1V alternator ● Turn engine start switch to OFF position. Move it to START position when performing troubleshooting. 9 Start relay Terminal SW and ground App. 24V Voltage Terminal S and ground App. 24V ● Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Failure of 10 ≤1 Ω parking unit Between CN-801F 2 and 3 Resistance Unplug connector CN-801F; measure resistance of motor coil. App 63 Ω
SA
Possible causes and standard value in normal state
3
TI N
2
LA
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform trouLow battery bleshooting. capacity ≥24V Battery voltage Voltage ● Turn engine start switch to OFF position. Keep it at OFF position to perform trouInternal failbleshooting. ure of start Resistance ≥1M Ω OFF position: between wire 22# and wire 11# switch ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Failure of ≤1 Ω pilot switch Lockout lever FREE position: between 105 # and 27# wire Resistance Lockout lever LOCKED position: between wire 105# and 27# ≥1 M Ω ● Turn engine start switch to OFF position. Keep the engine running during troubleshooting. (When all power supplies, grounding, signal and engine inputs are normal except engine output, it is the failure of start motor) Failure of Engine start motor Start switch Voltage start motor Power supply: Terminal B and ground 20~30V Start Between engine input terminal S and ground 20~30V ● Turn engine start switch to OFF position. Then, keep it at OFF position to perform troubleshooting. Open circuit Wire 21# and start motor terminal B ≤1 Ω of wire har-
A
Cause
Shop Manual - June 2013
7-65
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
START SWITCH B
TERMINAL
20
BATTERY
CN-241F (D-12)
20
1 2
21
F1
20A 22
F2
5A
OFF ON
10
START
9 12
RI C
A
BATTERY RELAY 21 1
2
3 4 5
1
2
3 4 5
11
10
2
12
22 13
22
1
9
BR ACC R1 R2 C
HEAT
PILOT SWITCH
105
F16 10A
0
AM E
LOCK RELAY
1
2
3 4 5
1
2
3 4 5
22
TI N
0
PARK RELAY
LA
CN-661F (S-16) 64 10 10 63 9 9 6 6 65
0
1 1
2 2
3 4 5 3 4 5
15 15
1
1
2
2
3
3
6
6
64 22 65 63
A B P1 P2
E 0
12a 14
12
47
21
12a 1 2 14 3 10 4 47
HLR CHARGE INDICATOR
1 2 3 4
SA
NY
13
CN-161F (S-16)
10 10
PARK MOTOR
CN-801F (H-6)
CN-613F (L-6)
10 12a 10 47
S
L
L S R P
B
10 14
SW
R L B P
S
B
ALTERNATOR
E
0
E
START RELAY
0
E
0
START MOTOR
SAFETY RELAY ZX215-1005095
7-66
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
Trouble
Engine Runs Rough or Is Unstable
Related information
Engine speed can be read on the monitor.
2
Internal failure in sensor
Short circuit of 3 wire harness (grounded) Internal failure 4 of controller
A
Open circuit of wire harness
RI C
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Unplug the connector controller, and measure Resistance 2.3±0.2 K Ω the resistance between pin 19 and pin 38. ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-448M A and B Resistance 2.3±0.2 K Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-448M B and ground Resistance ≥1M Ω No troubleshooting can be done due to internal failure. (Failure lies in the controller if the reasons above are ruled out)
AM E
Cause
TI N
5
CONTROLLER
NY
SPEED SENSOR INPUT SIGNAL
LA
Possible causes and standard value in normal state
E-2 Engine runs rough or is unstable
SA
GND
CN-448M （S-2）
38
A
19
B
CAB
SPEED SENSOR SIGNAL
GND
CHASSIS HARNESS
ZX215-1005096
Shop Manual - June 2013
7-67
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-3 Power supply of machine cannot be cut off Trouble Related information
Engine cannot be stopped. Engine stalls when start switch it turned to OFF position. There is no time delay for power cutout.
When engine start switch is operated, if the operation of battery Failure of batrelay contact is heard, the battery is normal. Turn the start switch tery relay OFF→ON→OFF. ● Turn engine start switch to OFF position. Keep it at OFF position to per-
RI C
Breakdown of form troubleshooting. 2 surge diode Between battery relay wire 20# and wire 21#
AM E
3
TI N
4
5
NY SA 7-68
A
1
Standard value in normal state/Remarks on troubleshooting
LA
Possible causes and standard value in normal state
Cause
Shop Manual - June 2013
Resistance ≥1M Ω
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
START SWITCH B
TERMINAL
20
BATTERY
CN-241F (D-12)
20
1 2
21
F1 F2
5A
OFF ON
10
START
9 12
21 2
3 4 5
1
2
3 4 5
RI C
A
BATTERY RELAY
1
11
10
2
12
22 13
22
1
9
BR ACC R1 R2 C
HEAT
20A 22
PILOT SWITCH
105
F16 10A
AM E
0
LOCK RELAY
1
2
3 4 5
1
2
3 4 5
TI N
0
PARK RELAY
CN-661F (S-16) 64 10 10 63 9 9 6 6 65
0 13
CN-161F (S-16) 10 10
1 1
2 2
3 4 5 3 4 5
15 15
1
1
2
2
3
3
6
6
64 22 65 63
A B P1 P2
E 0
12a 14
12
47
21
12a 1 2 14 3 10 4 47
HLR CHARGE INDICATOR
1 2 3 4
SA
PARK MOTOR
CN-801F (H-6)
NY
LA
22
CN-613F (L-6)
10 12a 10 47
S
L
L S R P
B
10 14
SW
R L B P
S
B
ALTERNATOR
E
0
E
START RELAY
0
E
0
START MOTOR
SAFETY RELAY ZX215-1005095
Shop Manual - June 2013
7-69
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-4 Auto idle not functioning Trouble Related information
Auto idle speed do not work Engine speed do not decrease wen the mode is auto idle speed and grip keeps still in "NEUTRAL" position
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Error of boom1 Levers in NEUTRAL, pressure signal transmitted 0 KG raise signal Pressure Lever in operation, pressure signal transmitted 0~39 KG ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Error of boom2 Levers in NEUTRAL, pressure signal transmitted 0 KG lower signal Pressure Lever in operation, pressure signal transmitted 0~39 KG ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Error of arm-in 3 0 KG Levers in NEUTRAL, pressure signal transmitted signal Pressure Lever in operation, pressure signal transmitted 0~39 KG ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Error of arm-out 4 Levers in NEUTRAL, pressure signal transmitted 0 KG signal Pressure Lever in operation, pressure signal transmitted 0~39 KG ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Error of bucket5 Levers in NEUTRAL, pressure signal transmitted 0 KG curl signal Pressure Lever in operation, pressure signal transmitted 0~39 KG ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Error of Bucket6 0 KG dump signal Levers in NEUTRAL, pressure signal transmitted Pressure Lever in operation, pressure signal transmitted 0~39 KG ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Error of swing 7 Levers in NEUTRAL, pressure signal transmitted 0 KG signal Pressure Lever in operation, pressure signal transmitted 0~39 KG ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. 8 Error of travel Levers in NEUTRAL, pressure signal transmitted 0 KG Pressure signal Lever in operation, pressure signal transmitted 0~39 KG ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Error of attach9 Levers in NEUTRAL, pressure signal transmitted 0 KG ment signal Pressure Lever in operation, pressure signal transmitted 0~39 KG Failure of con- No troubleshooting can be done for it is internal failure. (If it is not caused by 10 one of the factors listed above, it should be the failure of controller.) troller
7-70
AM E
TI N
LA
NY
SA
Possible causes and standard value in normal state
RI C
A
Cause
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-5 Preheating function fails Trouble
Engine does not preheat.
Related information Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform Failure of pretroubleshooting. 1 heat fuse Between wire 21# and preheat relay pin 3# (contact) Resistance ≤1 Ω When the preheating function is activated, if operation of the preheat relay Failure of pre2 contact is heard, the relay is normal. The preheat switch is to be switched heat relay OFF→ON→OFF. ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Failure of pre- Turn off the preheat switch and measure the resistance ≥1M Ω 3 heat switch between wire 16# and wire 18#. Resistance Turn on the preheat switch and measure the resistance ≤1 Ω between wire 16# and wire 18# Short circuit ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. of wire har4 ness (groundBetween preheat relay pin 3# (contact) and ground Resistance ≥1M Ω ed)
TI N
AM E
RI C
A
Possible causes and standard value in normal state
Cause
+
_
+
20
1 9
START SWITCH TERMINAL
B
BR ACC R1 R2 C
HEAT OFF ON
CN-241F (D-12) 1 9
NY
_
BATTERY
LA
5
START 22
20 F1 20A 22
13
16
22 16
SA
BATTERY RELAY 1
2 3 45
1
2 3 45
0
21
21
PREHEAT RELAY PREHEAT CN-142M SWITCH CN-131M (D-12) (D-12)
F13 160A
18
1 1
7 7
6 6
2 345 2 345
GR-1 GLOW PLUG
17
PREHEATER CHASSIS HARNESS
CAB
CHASSIS HARNESS
ZX215-1005097
Shop Manual - June 2013
7-71
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-6 Work equipment does not work Trouble
The machine is motionless while operated after starting.
Possible causes and standard value in normal state
Related information Cause
3
AM E
2
RI C
A
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Failure of lockout Item Lockout control lever Resistance switch LOCK ≤1 Ω Between wire 105# and wire 27# FREE ≥1M Ω Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. wire harness ≥1M Ω Between 105# and ground Resistance (grounded) Failure of coil ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. inside lockout Resistance About 34 Ω Between CN-136F 1 and 2 solenoid valve
TI N
4
PILOT SWITCH
CN-106F （AMP-2） F16 10A 21
27
2
2
1
1
27
2
2
105
CN-161F (S-16)
LA
B-
10 10
SA
NY
12 12
0 1 1
105 2 2
27 606 3 45 3 45
CN-661F CN-136F （S-16） （AMP-2） 1
1
1
1
8
8
2
2
PILOT SOLENOID VALVE
CAB
CHASSIS HARNESS
ZX215-1005098
7-72
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-7 Boom-raise speed or power is low Trouble
Boom-raise speed or power is low. Pilot pressure of the boom in operation can be checked on the monitor.
Failure of sensor
2
Short circuit of harness (grounded)
3
Open circuit of harness
4
Failure of controller
AM E
RI C
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Levers in NEUTRAL, boom-raise pressure signal 0 KG Pressure Lever in operation, boom-raise pressure signal 0~39 KG ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between harness ( from controller pin 70 to CN-126M Resistance ≥1M Ω A) and ground ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. ≤1 Ω Between controller pin 54 and CN-126M B Resistance No troubleshooting can be done due to internal failure. (Failure lies in the controller if the reasons above are ruled out)
A
Cause
CONTROLLER
BOOM UP PRESSURE SENSOR SENSOR GND WIRE
70
SENSOR 5V
TI N
Possible causes and standard value in normal state
Related information
CN-126M （DF-3）
BOOM UP PRESS. SENSOR SIGNAL
54
B
GND WIRE
56
C
NY
LA
A
CAB
5V
CHASSIS HARNESS
SA
ZX215-1005099
Shop Manual - June 2013
7-73
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-8 Arm speed or power is low Trouble
Arm speed or power is low during operation.
Related information
Pilot pressure of the arm in operation can be checked on the monitor.
3
4
A
RI C
AM E
2
TI N
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Failure of sen- Levers in NEUTRAL, arm-in and arm-out pressure 0 KG signals sor Pressure Levers in operation, arm-in and dump pressure 0~39 KG signal ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Short circuit Between harness (from controller pin 71 to CNof harness 128M A) and ground Resistance ≥1M Ω (grounded) Between harness (from controller pin 52 to CN122M A) and ground ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between controller pin 54 and CN-128M B harness ≤1 Ω Resistance Between controller pin 54 and CN-122M B Failure of con- No troubleshooting can be done due to internal failure. (Failure lies in the troller controller if the reasons above are ruled out)
NY
LA
Possible causes and standard value in normal state
Cause
CN-122M （DF-3）
ARM-OUT PRESS. SENSOR
A
SIGNAL
B
GND WIRE 5V
C
SA
CONTROLLER
ARM-OUT PRESS SENSOR
52
CN-128M （DF-3）
ARM-IN PRESS SENSOR
71
A
SIGNAL
SENSOR GND WIRE
54
B
GND WIRE
SENOSR 5V
56
C
CAB
ARM-IN PRESS. SENSOR
5V
CHASSIS HARNESS
ZX215-1005119
7-74
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-9 Bucket speed or power is low Trouble
Bucket speed or power is low during operation.
Related information
Pilot pressure of the bucket can be checked on the monitor.
4
confluence About 17.5 Between CN-134F 1 and 2 Resistance solenoid Ω valve Failure of No troubleshooting can be done due to internal failure. (Failure lies in the controlcontroller ler if the reasons above are ruled out)
SA
NY
5
TI N
AM E
RI C
A
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Failure of 1 Levers in NEUTRAL, bucket-curl/dump pressure signals 0 KG sensor Pressure Levers in operation, bucket-curl/dump pressure signals 0~39 KG ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Short circuit Between harness (from controller pin 69 to CN-124M A) 2 of harness and ground (grounded) Between harness (from controller pin 50 to CN-127M A) Resistance ≥1M Ω and ground ● Turn engine start switch to OFF position. Keep it at OFF position to perform Open circuit troubleshooting. 3 Between controller pin 54 and CN-124M B of harness ≤1 Ω Resistance Between controller pin 54 and CN-127M B Defective ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. bucket
LA
Possible causes and standard value in normal state
Cause
Shop Manual - June 2013
7-75
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
CN-127M （DF-3）
BUCKET-DUMP PRESS. SENSOR
A
SIGNAL
B
GND WIRE
C
5V
50
CN-124M （DF-3）
BUCKET-DUMP PRESS. SENSOR
69
A
SENSOR GND WIRE
54
B
SENOSR 5V
56
C
BUCKET CONFLUENCE SIGNAL
99
SIGNAL GND WIRE
AM E
5V
BUCKET CONFLUENCE PROPORTIONAL VALVE
1
SIGNAL
2
GND WIRE
LA
TI N
CN-134F （AMP-2）
CAB
BUCKET-CURL PRESS. SENSOR
RI C
BUCKET-CURL PRESS. SENSOR
A
CONTROLLER
CHASSIS HARNESS
SA
NY
ZX215-1005100
7-76
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
Trouble
Travel speed or power is low during operation.
Related information
Pilot pressure of travel operation can be checked on the monitor.
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Failure of sen- Levers in NEUTRAL, left and right travel pressure 0 KG 1 signals sor Pressure Levers in operation, left and right travel pressure 0~39 KG signals ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Short circuit Between harness (from controller pin 49 to CN2 of harness 120M A) and ground Resistance ≥1M Ω (grounded) Between harness (from controller pin 67 to CN-
AM E
RI C
A
Cause
TI N
121M A) and ground ● Turn engine start switch to OFF position. Keep it at OFF position to perform Open circuit of troubleshooting. 3 Between controller pin 54 and CN-120M B Beharness ≤1 Ω Resistance tween controller pin 54 and CN-121M B Failure of con- No troubleshooting can be done due to internal failure. (Failure lies in the con4 troller troller if the reasons above are ruled out)
NY
LA
Possible causes and standard value in normal state
E-10 Travel speed or power is low
CN-121M （DF-3）
RIGHT TRAVEL PRESS. SENSOR
A
SIGNAL
B
GND WIRE
C
5V
CONTROLLER
LEFT TRAVEL PRESS. SENSOR
67
CN-120M （DF-3）
49
A
SIGNAL
SENSOR GND WIRE
54
B
GND WIRE
SENOSR 5V
56
C
SA
RIGHT TRAVEL PRESS SENSOR LEFT TRAVEL PRESS SENSOR
5V
CHASSIS HARNESS
CAB
ZX215-1005101
Shop Manual - June 2013
7-77
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-11 Blank monitor display Trouble
Monitor display is blank after the machine is powered on.
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. 1 Failure of fuse Between wire 22# and ground About 24V Voltage About 24V Between wire 29# and ground ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-7-705 pin 8 and CN-241F pin 3 ≤1 Ω 2 wire harness Between CN-7-705 pin 9 and CN-241 pin 1 Resistance ≤1 Ω
RI C
A
Cause
AM E
Between CN-7-705 pin 10# and ground ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Short circuit of Between harness (from CN-7-705 pin 8 to CN-241 ≥1M Ω 3 wire harness pin 3) and ground Resistance (grounded) Between harness (from CN-7-705 pin 9 to CN-241 ≥1M Ω pin 1) and ground Failure of No troubleshooting can be done for it is internal failure. (If it is not caused by 4 monitor one of the factors listed above, it should be the failure of monitor.) CN-1-112 (D-3)
LA
CANH
TI N
Possible causes and standard value in normal state
Related information
CANL
CN-1-111 (D-6) 1 1 2 2 3 3
60 78
SA
CANL
120ȍ RESISTANCE
2 2
3 3 1 1 CN-241F (D-12)
CANH CANL 29 22 0
CN-7-705 (D-12) 3 3 4 4 8 8 9 9 10 10 12 12
22
29
3 4 8 9 10 12 F1
20A
F10
5A
MONITOR
CANH
NY
CONTROLLER
1 1
20
21 PWR
CAB
PWR
CHASSIS HARNESS ZX215-1005102
7-78
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-12 Monitor displays nothing Display of monitor is illuminated but no information is shown on the screen after machine is powered on.
Trouble
3
4
Between CN-1-112 1 and 2
Resistance
120 Ω
RI C
2
Failure of resistance
● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-7-705 pin 3 and controller pin 60 ≤1 Ω wire harness Resistance Between CN-7-705 pin 4 and controller pin 78 ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Short circuit of Between harness (from CN-7-705 pin 3 to con≥1M Ω wire harness troller pin 60) and ground Resistance (grounded) Between harness (from CN-7-705 pin 4 to control≥1M Ω ler pin 78) and ground Failure of monitor No troubleshooting can be done for it is internal failure. (If it is not one of or controller the failures stated above, it should be the failure of monitor or controller.)
AM E
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting.
A
Cause
TI N
Possible causes and standard value in normal state
Related information
LA
CANH
CN-1-112 (D-3)
CANL
60
CANL
78
SA
CANH
120ȍ RESISTANCE
2 2
CN-1-111 (D-6) 1 1 2 2 3 3
3 3 1 1 CN-241F (D-12)
CANH CANL 29 22 0
CN-7-705 (D-12) 3 3 4 4 8 8 9 9 10 10 12 12
22
29
3 4 8 9 10 12 F1
20A
F10
5A
MONITOR
NY
CONTROLLER
1 1
20
21 PWR
CAB
PWR
CHASSIS HARNESS ZX215-1005102
Shop Manual - June 2013
7-79
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
Trouble
Only low speed travel is functioning during operation.
Related information
Press the Hi/Lo button on the monitor to change travel speed.
AM E
RI C
A
Cause Standard value in normal state/Remarks on troubleshooting Failure of dual ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. 1 speed travel Between CN-131F A and B Resistance About 17.5 Ω solenoid valve ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of 2 Between CN-132F pin A and controller pin 100 ≤1 Ω wire harness Resistance Between CN-132F pin B and controller pin 55 ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform Short circuit of troubleshooting. 3 wire harness Between harness (from CN-132F pin A to conResistance ≥1M Ω (grounded) troller pin (100) and ground 4
CONTROLLER
GROUND
100
55
LA
HIGH SPEED TRAVEL SOLENOID VALVE
TI N
Possible causes and standard value in normal state
E-13 Dual speed travel not functioning
A
SIGNAL
B
GND WIRE
ZX215-1005104
SA 7-80
HIGH SPEED TRAVEL SOLENOID VALVE
CHASSIS HARNESS
NY
CAB
CN-132F （AMP-2）
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-14 Incorrect engine coolant reading Engine coolant temperature sensor cannot correctly reflect current coolant temperature. Coolant temperature can be checked on the monitor.
Trouble Related information
Standard value in normal state/Remarks on troubleshooting Standard values for engine coolant temperature sensor 60°C
Failure of coolant temperature sensor
56.3 Ω
RI C
1
80 Ω
A
50°C 80°C
29.5 Ω
100°C
16.5 Ω
106°C
14.3 Ω
3
4
10 Ω
● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting.
Resistance Between wire 510# and controller pin 30 ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to Short circuit of perform troubleshooting. lead (grounded) Between wire 510# and ground Resistance ≥1M Ω ● Turn engine start switch to OFF position. Keep it at OFF position to Lead short to 24V perform troubleshooting. circuit Voltage ≤1V Wire 510# to ground
TI N
2
Open circuit of lead
AM E
120°C
NY
ࠊ఼
LA
Possible causes and standard value in normal state
Cause
SA
⏽⎆ैދᑺӴᛳ఼
30
510
偒偊ᅸ
䔺䑿㒓ᴳ
ZX215-1005105
Shop Manual - June 2013
7-81
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
Trouble
Engine fuel level sensor cannot correctly reflect current fuel level.
Related information
Fuel level can be checked on the monitor.
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Fuel level senFuel level Pin Resistance 1 sor error FULL (Upper limit) Approx. 10 Ω Between wire 509# and ground
Open circuit of lead
Short circuit of 3 lead (grounded) 4
Lead short to 24V
EMPTY (Lower limit) 85-95 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Resistance Between wire 509# and controller pin 11 ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Resistance Between wire 509# and ground ≥1M Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Voltage ≤1V Wire 509# grounded
AM E
2
RI C
A
Cause
TI N
Possible causes and standard value in normal state
E-15 Incorrect fuel level reading
LA
CONTROLLER
FUEL LEVEL SENSOR
509
NY
11
CAB
SA
CHASSIS HARNESS
7-82
ZX215-1005106
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-16 Wiper does not work Trouble
Wiper does not work
RI C
A
Cause Standard value in normal state/Remarks on troubleshooting Internal Fail- ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. 1 ure of wiper Resistance Between wiper wire 25# and ground >10 Ω motor ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Open circuit of Between CN-241F 1 and CN-1-110 (2) ≤1 Ω 2 lead Between wiper switch wire 35L# and CN-1-110 (5) Resistance ≤1 Ω
AM E
Between wiper switch wire 35L# and CN-1-110 (4) ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform Short circuit of troubleshooting. 3 lead (ground- Harness from CN-241F 1 to CN-1-110 2 short to Resistance ≥1M Ω ed) ground 4
TI N
Possible causes and standard value in normal state
Related information
WIPER SWITCH
CN-132M （D-12）
F15 5A
25
1 21
SA
PWR
1
25
3
3
4
4
36 35L 35H
CN-113F （D-12）
4
CN-1-110 （D-6）
2
2
3
3
4
4
5
5
25 36 35L
M
35H
NY
CN-241M （D-12）
11
1
LA
CN-121F （D-12）
CAB
ZX215-1005107
Shop Manual - June 2013
7-83
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-17 Incorrect arm-in pilot pressure reading Trouble
Reading of arm-in pilot pressure is incorrect.
3
4
RI C
2
Failure of sensor
AM E
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of 5V perform troubleshooting. power supply Between CN-128M ① and ③ Voltage Approx. 5V ● Turn engine start switch to OFF position. Keep it at OFF position to perOpen circuit of form troubleshooting. signal wire Between CN-128M ② and controller pin 71 Resistance ≤Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Short circuit of signal wire Resistance ≥2M Ω Between CN-128M ② and ground
A
Cause
● Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. 0.5V~ 4.5V Between CN-128M ② and ground Voltage
5
TI N
Possible causes and standard value in normal state
Related information
LA
CONTROLLER
ARM IN PRESS SENSOR
71
2
SIGNAL
SENSOR GND WIRE
55
3
GND WIRE
SENSOR 5V
75
1
5V
NY
ARM IN PRESS SENSOR
SA 7-84
CN-128M （DF-3）
CAB
CHASSIS HARNESS
ZX215-1005108
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-18 Incorrect arm-out pilot pressure reading Trouble
Reading of arm-out pilot pressure is incorrect.
3
Short circuit of signal wire
4
Failure of sensor
●
●
●
A
2
Open circuit of signal wire
●
RI C
1
Failure of 5V power supply
Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-122M ① and ③ Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-122M ② and controller pin 52 Resistance ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Resistance ≥2M Ω Between CN-122M ② and ground Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. 0.5V~ 4.5V Between CN-122M ② and ground Voltage
AM E
Cause
5
TI N
Possible causes and standard value in normal state
Related information
ARM OUT PRESS SENSOR
LA
CONTROLLER
CN-122M （DF-3）
ARM OUT PRESS SENSOR
2
SIGNAL
SENSOR GND WIRE
55
3
GND WIRE
SENSOR 5V
75
1
NY
52
CHASSIS HARNESS
SA
CAB
5V
ZX215-1005109
Shop Manual - June 2013
7-85
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-19 Incorrect boom-raise pilot pressure reading Trouble
Incorrect Boom-Raise Pilot Pressure Reading
Cause
4
Failure of sensor
A
3
Short circuit of signal wire
●
RI C
2
Open circuit of signal wire
●
●
AM E
1
Failure of 5V power supply
Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-126M ① and ③ Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-126M ② and controller pin 70 Resistance ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Resistance ≥2M Ω Between CN-126M ② and ground Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. 0.5V~ 4.5V Between CN-126M ② and ground Voltage
●
5
TI N
Possible causes and standard value in normal state
Related information
LA
CONTROLLER
BOOM UP PRESS SENSOR
70
2
SIGNAL
SENSOR GND WIRE
55
3
GND WIRE
SENSOR 5V
75
1
5V
NY
BOOM UP PRESS SENSOR
CHASSIS HARNESS
SA
CAB
7-86
CN-126M （DF-3）
ZX215-1005110
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-20 Incorrect boom-lower pilot pressure reading Trouble
Boom-Lower pilot pressure reading is incorrect.
3
Short circuit of signal wire
4
Failure of sensor
●
●
●
A
2
Open circuit of signal wire
●
RI C
1
Failure of 5V power supply
Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-125M ① and ③ Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-125M ② and controller pin 51 Resistance ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Resistance ≥2M Ω Between CN-125M ② and ground Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. 0.5V~ 4.5V Between CN-125M ② and ground Voltage
AM E
Cause
5
TI N
Possible causes and standard value in normal state
Related information
BOOM DOWN PRESS SENSOR
LA
CONTROLLER
SENSOR GND WIRE
BOOM DOWN PRESS SENSOR
51
2
SIGNAL
55
3
GND WIRE
75
1
5V
NY
SENSOR 5V
CN-125M （DF-3）
CAB
SA
CHASSIS HARNESS
ZX215-1005111
Shop Manual - June 2013
7-87
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-21 Incorrect bucket-curl pilot pressure reading Trouble
Bucket-curl pilot pressure reading is incorrect.
3
Short circuit of signal wire
4
Failure of sensor
●
●
●
A
2
Open circuit of signal wire
●
RI C
1
Failure of 5V power supply
Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-124M ① and ③ Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-124M ② and controller pin 69 Resistance ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Resistance ≥2M Ω Between CN-124M ② and ground Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. 0.5V~ 4.5V Between CN-124M ② and ground Voltage
AM E
Cause
5
TI N
Possible causes and standard value in normal state
Related information
CONTROLLER
BUCKET CURL PRESS SENSOR
69
2
SIGNAL
SENSOR GND WIRE
55
3
GND WIRE
SENSOR 5V
75
1
5V
NY
LA
BUCKET CURL PRESS SENSOR
CHASSIS HARNESS
SA
CAB
7-88
CN-124M （DF-3）
ZX215-1005112
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-22 Incorrect bucket-dump pilot pressure reading Trouble
Bucket-dump pilot pressure reading is incorrect.
3
4
RI C
2
AM E
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of 5V perform troubleshooting. power supply Between CN-127M ① and ③ Voltage About 5V ● Turn engine start switch to OFF position. Keep it at OFF position to perOpen circuit of form troubleshooting. signal wire Between CN-127M ② and controller pin 50 Resistance ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perShort circuit of form troubleshooting. signal wire Resistance ≥2M Ω Between CN-127M ② and ground ● Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Failure of sensor 0.5V~ 4.5V Between CN-127M ② and ground Voltage
A
Cause
5
CONTROLLER
50
LA
BUCKET DUMP PRESS SENSOR
TI N
Possible causes and standard value in normal state
Related information
CN-127M （DF-3） 2
SIGNAL GND WIRE
SENSOR GND WIRE
55
3
SENSOR 5V
75
1
NY
BUCKET DUMP PRESS SENSOR
5V
CHASSIS HARNESS
SA
CAB
ZX215-1005113
Shop Manual - June 2013
7-89
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-23 Incorrect swing pilot pressure reading Trouble
Swing pilot pressure reading is incorrect.
3
4
RI C
2
AM E
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position Failure of 5V to perform troubleshooting. power supply Between CN-123M ① and ③ Voltage About 5V ● Turn engine start switch to OFF position. Keep it at OFF position to perOpen circuit of form troubleshooting. signal wire Between CN-123M ② and controller pin 68 Resistance ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perShort circuit of form troubleshooting. signal wire Resistance ≥2M Ω Between CN-123M ② and ground ● Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Failure of sensor 0.5V~ 4.5V Between CN-123M ② and ground Voltage
A
Cause
5
TI N
Possible causes and standard value in normal state
Related information
CONTROLLER
SWING PILOT PRESS SENSOR
68
2
SIGNAL
SENSOR GND WIRE
55
3
GND WIRE
SENSOR 5V
75
1
5V
NY
LA
SWING PILOT PRESS SENSOR
CHASSIS HARNESS
SA
CAB
7-90
CN-123M （DF-3）
ZX215-1005114
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-24 Incorrect left travel pilot pressure reading Trouble
Left Travel Pilot Pressure Reading is incorrect.
3
Short circuit of signal wire
●
●
● 4
Failure of sensor
A
2
Open circuit of signal wire
●
RI C
1
Failure of 5V power supply
Standard value in normal state/Remarks on troubleshooting Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. Between CN-120M ① and ③ Voltage About 5V Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Between CN-120M ② and controller pin 49 Resistance ≤1 Ω Turn engine start switch to OFF position. Keep it at OFF position to perform troubleshooting. Resistance ≥2M Ω Between CN-120M ② and ground Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting. 0.5V~ 4.5V Between CN-120M ② and ground Voltage
AM E
Cause
5
TI N
Possible causes and standard value in normal state
Related information
CONTROLLER
CN-120M （DF-3）
LEFT TRAVEL PILOT PRESSURE SENSOR
49
2
SENSOR GND WIRE
55
3
GND WIRE
75
1
5V
NY
SENSOR 5V
LA
LEFT TRAVEL PILOT PRESSURE SENSOR
SIGNAL
CHASSIS HARNESS
SA
CAB
ZX215-1005115
Shop Manual - June 2013
7-91
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
E-25 Incorrect right travel pilot pressure reading Trouble
Right travel pilot pressure reading is incorrect.
3
4
RI C
2
AM E
1
Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of 5V perform troubleshooting. power supply Between CN-121M ① and ③ Voltage About 5V ● Turn engine start switch to OFF position. Keep it at OFF position to perOpen circuit of form troubleshooting. signal wire Between CN-121M ② and controller pin 67 Resistance ≤1 Ω ● Turn engine start switch to OFF position. Keep it at OFF position to perShort circuit of form troubleshooting. signal wire Resistance ≥2M Ω Between CN-121M ② and ground ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of senperform troubleshooting. sor 0.5V~ 4.5V Between CN-121M ② and ground Voltage
A
Cause
5
TI N
Possible causes and standard value in normal state
Related information
CN-121M （DF-3）
LA
CONTROLLER
RIGHT TRAVEL PILOT PRESSURE SENSOR
67
2
SIGNAL
SENSOR GND WIRE
55
3
GND WIRE
75
1
NY
SENSOR 5V
5V
CHASSIS HARNESS
SA
CAB
7-92
RIGHT TRAVEL PILOT PRESSURE SENSOR
ZX215-1005116
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
7.7 Troubleshooting of Hydraulic and Mechanical Systems (H - Mode)
SA
NY
LA
TI N
AM E
RI C
A
A Schematic of hydraulic system and mechanical system ........................................................ 7-94 Information contained in troubleshooting table .......................................................................... 7-96 H-1 Work equipment speed slow, or swing and travel speeds slow ......................................... 7-97 H-2 Engine speed drops sharply or engine stalls ..................................................................... 7-98 H-3 Work equipment, swing, and travel systems do not work .................................................. 7-99 H-4 Abnormal noise in hydraulic pump ................................................................................... 7-100 H-5 Auto deceleration not functioning..................................................................................... 7-101 H-6 Boom speed slow ............................................................................................................ 7-102 H-7 Arm speed slow ............................................................................................................... 7-103 H-8 Bucket speed slow ........................................................................................................... 7-104 H-9 Work equipment cylinders no response in separate operation ....................................... 7-105 H-10 Work equipment drifts excessively ................................................................................ 7-106 H-11 Work equipment moves sluggishly ............................................................................... 7-108 H-12 Other work equipment moves while single oil circuit is relieved .................................... 7-108 H-13 Travel speed drops considerably while swinging and travelling .................................... 7-109 H-14 Machine deviates during travel ...................................................................................... 7-110 H-15 Travel speed is low .........................................................................................................7-111 H-16 Machine is not steered well or steering power is low..................................................... 7-112 H-17 Travel speed cannot be changed................................................................................... 7-113 H-18 Travel system fails (only at one side)............................................................................. 7-114 H-19 Swing operation fails...................................................................................................... 7-115 H-20 Swing acceleration poor or swing speed low ................................................................. 7-117 H-21 Upper structure overruns remarkably when it stops swinging ....................................... 7-119 H-22 Large shock is produced when upper structure stops swinging .................................... 7-120 H-23 High noise is produced when upper structure stops swinging ....................................... 7-120 H-24 Swing drift excessive ..................................................................................................... 7-121
Shop Manual - June 2013
7-93
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
A Schematic of hydraulic system and mechanical system
PILOT VALVE - R
A
DUMP
BUCKET CURL
BOOM LOWER
BWD
FWD
FWD
RIGHT
LEFT
BWD
TRAVEL TRAVEL (LEFT) (RIGHT)
SWING
OUT
IN
ARM
PILOT VALVE - TRAVEL
RAISE
PILOT VALVE - L
RI C
LOCK (PILOT VALVE )
16
BOOM PRIORITY
1
2
3
4
5
6
7
8
9
10 11 12
15
BUCKET CONFLUENCE
14
SWING PRIORITY
AM E
ACCUMULATOR
13
VARIABLE SPEED (TRAVEL)
TI N
1 2
19
3
LA
20
18
NY
17
SA
REGULATOR
REGULATOR
SERVO MECHANISM
SERVO MECHANISM
P1
P2
M
FRONT
REAR
ZX225-1105039
7-94
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
● The system schematic is a simplified hydraulic circuit schematic, which can be used as a reference to the hydraulic system and the mechanical system.
12
BOOM CYLINDER
9
S&S
5
Su
BOOM VALVE
S&S
10
BACKUP VALVE
L. TRAVEL VALVE
Su
6
S&S
BACKUP ACTUATOR
9
BOOM 2
3
4
SWING VALVE
SWING MOTOR
1 2
Su
8
SERVO MECHANISM
R. TRAVEL VALVE
Sa
Su
LA
TRAVEL MOTOR (L)
7
Sa
STRT. TRAVEL VALVE
BALANCE VALVE
TI N
SERVO MECHANISM
13
Sa
Sa
13 BALANCE VALVE
S&S
9
ANTISWING ANTISWING VALVE VALVE
S&S
BUCKET CYLINDER
Su
BUCKET VALVE
2
Su
S&S
VALVE S&S ARM S&S REG. VALVE
14
Sa
11
1
2
ARM 2 VALVE
BOOM HOLD VALVE
10
1
15
AM E
ARM HOLD VALVE
BUCKET CYLINDER
BUCKET CONFLUENCE
BACKUP VALVE CONFLUENCE
RI C
1
A
6D SAFETY VALVE 6X SUCTION VALVE 6 6 SAFETY&SUCTION
TRAVEL MOTOR (R)
NY
3
SA
ZX225-1105040
Shop Manual - June 2013
7-95
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
Information contained in troubleshooting table
Trouble which occurs on the machine
Related information
Information related to detected trouble or troubleshooting
A
Trouble
Standard value in normal state/Remarks on troubleshooting
RI C
Cause 1
4
Possible causes of < Description > trouble (Given numbers ● Standard value in normal state, which is used to judge possible are reference numbers, causes that might be OK or N/G. which do not indicate ● A reference value is used to determine OK or N/G. priority)
TI N
3
AM E
2
LA
5
SA
NY
Possible causes and standard value in normal state
● The following information is contained in the troubleshooting table and related electric circuit diagrams. Fully understand these information before carrying out troubleshooting.
7-96
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-1 Work equipment speed slow, or swing and travel speeds slow Trouble Related information
2
A
Control levers
Main relief pressure 33~34.3 MPa {337~350 kg/cm²}
Arm in
AM E
valve
RI C
Defective adjustment or malfunction of main relief
● Stop the engine. Perform troubleshooting while the engine is running at high idle.
If normal pressure cannot be restored after adjustment, it is possible the failure of main relief valve or internal defect. Check the valve directly. ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Control levers Pilot control pressure
Malfunction of pilot relief valve
TI N
1
Standard value in normal state/Remarks on troubleshooting
All levers in "NEUTRAL"
3.9~4.1 MPa {40~42 kg/cm²}
3
Malfunction of regulator
4
Malfunction of If the trouble is caused by other factors, it might be the main pump that has main pump performance deterioration, malfunction or internal defect.
LA
The regulator possibly fails. Check the servo mechanism of the regulator.
SA
NY
Possible causes and standard value in normal state
Cause
● Work equipment speed is slow or the travel and swing speeds are slow. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
Shop Manual - June 2013
7-97
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-2 Engine speed drops sharply or engine stalls Trouble
● Engine speed drops sharply or engine stalls. ● Information concerned
Cause
Standard value in normal state/Remarks on troubleshooting
1
Failure of injection pump Injection pump may be defective. Check it directly.
2
Malfunction of regulator
4
A
Clogging of oil filter element Carbon buildup at fuel injection nozzle
RI C
3
Regulator may have malfunction. Check its servo mechanism. Oil filter element may be clogged. Check the element directly. Carbon built up at fuel injection nozzle. Check it directly.
Clogging of air cleaner
Air cleaner may be clogged. Check it directly.
6
Abnormal wear of engine Engine may be worn abnormally. Check it directly.
7
Failure of oil pump
AM E
5
Oil pump may be defective. Check it directly.
SA
NY
LA
TI N
Possible causes and standard value in normal state
Related information
7-98
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-3 Work equipment, swing, and travel systems do not work Trouble Related information
A
Malfunction of pilot relief solenoid valve
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Pilot lockout control lever Pilot relief pressure LOCKED
AM E
The main pump may have malfunction or internal defect. Check it by Failure of hydraulic following method. pump ● Remove the oil pressure measurement plug and start the engine. If oil flows out of the opening, the piston pump is in good condition. Internal failure of the coupling can stop rotation of the pump shaft. Check the coupling. Failure of coupling ● Loosen the oil delivery line of the pilot pump. If no oil is seen, it is probably the failure of coupling.
SA
NY
4
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Failure of relief valve Control lever Pilot relief pressure (pilot pump) 3.9~4.1 MPa All levers in "NEUTRAL" {40~42 kg/cm²}
TI N
3
0 {0}
3.9~4.1 MPa {40~42 kg/cm²}
FREE
2
RI C
1
Standard value in normal state/Remarks on troubleshooting
LA
Possible causes and standard value in normal state
Cause
● Whole work equipment, swing, and travel systems do not work. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
Shop Manual - June 2013
7-99
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-4 Abnormal noise in hydraulic pump Trouble
● Abnormal noise is produced from the hydraulic pump ―
Cause
Standard value in normal state/Remarks on troubleshooting
1
Low level of hydraulic oil
2
Inferior hydrauHydraulic oil probably contains air. Make a visual check. lic oil
4
5
It is probably the clogging of hydraulic tank strainer that causes negative pressure in the oil suction line. Make a visual check.
Failure of main The main pump may have internal defect. Check the main pump. pump
LA NY SA 7-100
A
RI C
It is probably the clogging of the vent on top of the hydraulic tank that causes negative pressure in the hydraulic tank. Press the release button of the breather valve to eliminate air. Check again if the noise disappears.
AM E
3
Clogging of vent on top of hydraulic tank Clogging of hydraulic tank strainer
Make a visual check.
TI N
Possible causes and standard value in normal state
Related information
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-5 Auto deceleration not functioning Trouble
Cause
A
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Control levers Pilot valve output pressure Malfunction "NEUTRAL" 0 {0} of sensor
RI C
1
Standard value in normal state/Remarks on troubleshooting
3.5~4.1MPa {36~42 kg/cm²}
Operation
Operation Failure of controller
3.5~4.1MPa {36~42 kg/cm²}
TI N
3
AM E
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Control levers Pilot valve output pressure Malfunction 2 "NEUTRAL" 0 {0} of pilot valve
Controller may be defective. Check it directly.
SA
NY
LA
Possible causes and standard value in normal state
Related information
● Auto-deceleration is not functioning. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
Shop Manual - June 2013
7-101
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-6 Boom speed slow Trouble
● The boom moves slowly. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
Related information
Standard value in normal state/Remarks on troubleshooting
A
"NEUTRAL"
0 {0}
Boom RAISE Boom LOWER
≥3.5MPa {36 kg/cm²}
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Check the pressure sensor by replacing it with a new one.
AM E
Failure of pressure 2 sensor
Malfunction of boom Spool of boom control valve may have malfunction. Check it directly. control valve (spool) Malfunction of boom Retaining valve of boom control valve may have malfunction. Check the 4 control valve (revalve directly. taining valve) Malfunction or defective seal of boom The relief valve and makeup valve in boom control valve may have mal5 control valve function or defective seal. Check the valves directly. (Relief valve and makeup valve) ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Charge the bucket with a load of approximate 1260 kg. Cut off the oil passage to the high-pressure side of the cylinder. Disconnect the cylinFailure of boom der from the main valve. Measure the displacement of piston for 15 min6 cylinder utes after the cylinder becomes stable. If the measured value is greater than 10 mm, it is deemed that cylinder has a defective seal. For more information on the measuring procedure refer to "Testing and Adjusting", "Hydraulic Drift (Work Equipment) - Test".
LA
TI N
3
SA
NY
Possible causes and standard value in normal state
Malfunction of right 1 pilot valve (boom circuit)
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Boom control lever Pilot valve output pressure
RI C
Cause
7-102
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-7 Arm speed slow Trouble
● The arm moves slowly. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
Related information
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Arm control lever Pilot valve output pressure
A
Malfunction of left pilot valve (arm circuit)
"NEUTRAL" Arm IN or Arm OUT
4
LA
5
AM E
3
≥3.5MPa {36 kg/cm²}
TI N
2
0 {0}
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Failure of pressure sensor Check the pressure sensor by replacing it with a new one. Malfunction of arm control Spool of arm control valve may have malfunction. Check it directly. valve (spool) Malfunction of arm control Regeneration valve of arm control valve may have malfunction. valve (regeneration valve) Check it directly. Malfunction or defective seal of arm control valve The relief valve or makeup valve inside the arm control valve may (Relief valve and makeup have malfunction or defective seal. Check the valves directly. valve) ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Cut off the oil passage to the high-pressure side of the cylinder. Failure of arm cylinder
SA
6
NY
Possible causes and standard value in normal state
1
Standard value in normal state/Remarks on troubleshooting
RI C
Cause
Disconnect the cylinder from the main valve. Measure the displacement of piston for 15 minutes after the cylinder becomes stable. If the measured value is greater than 10 mm, it is deemed that cylinder has a defective seal. For more information on the measuring procedure refer to "Testing and Adjusting", "Hydraulic Drift (Work Equipment) - Test".
Shop Manual - June 2013
7-103
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-8 Bucket speed slow Trouble
● The bucket moves slowly. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
Related information
Standard value in normal state/Remarks on troubleshooting
2
Failure of pressure sensor
RI C
AM E
Malfunction of bucket control valve Spool of bucket control valve may have malfunction. Check it directly. (spool) Malfunction or defective seal of Relief valve and makeup valve in bucket control valve may have malbucket control valve function or defective seal. Check the valves directly. (relief valve and makeup valve) ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Charge the bucket with a load of approximate 1260 kg. Cut off the oil passage to the high-pressure side of the cylinder. Disconnect the cylinFailure of bucket der from the main valve. Measure the displacement of piston for 15 mincylinder utes after the cylinder becomes stable. If the measured value is greater than 10 mm, it is deemed that cylinder has a defective seal. For more information on the measuring procedure refer to "Testing and Adjusting", "Hydraulic Drift (Work Equipment) - Test".
LA
4
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Check the pressure sensor by replacing it with a new one.
TI N
3
A
1
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Malfunction of right Bucket control lever Pilot valve output pressure pilot valve (bucket "NEUTRAL" 0 {0} circuit) ≥3.5MPa Bucket CURL or Bucket DUMP {36 kg/cm²}
SA
5
NY
Possible causes and standard value in normal state
Cause
7-104
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-9 Work equipment cylinders no response in separate operation ● Boom cylinder gives no response in separate operation. ● Arm cylinder gives no response in separate operation. ● Bucket cylinder gives no response in separate operation.
Trouble
● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting. Standard value in normal state/Remarks on troubleshooting
A
Cause
1
Malfunction of pilot valve
"NEUTRAL"
AM E
DIG or DUMP
RI C
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Work equipment control lever Pilot valve output pressure 0 {0}
≥3.5MPa {36 kg/cm²}
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Check the pressure sensor by replacing it with a new one.
3
Malfunction of control valve (spool)
Spool of control valve may have malfunction. Check it directly.
TI N
2
Failure of pressure sensor
SA
NY
LA
Possible causes and standard value in normal state
Related information
Shop Manual - June 2013
7-105
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-10 Work equipment drifts excessively Trouble (1)
● The boom drifts at excessive speed. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
Related information
Standard value in normal state/Remarks on troubleshooting
3
4
AM E
2
tive seal. For more information on the measuring procedure refer to "Testing and Adjusting", "Hydraulic Drift (Work Equipment) - Test". Failure of boom retain- Boom retaining valve or pilot valve may be worn or sluggish. Check ing valve the valves. Malfunction or defective seal of boom control The relief valve and the makeup valve in the boom control valve valve (relief valve and may have a defective seal. Check the seals. makeup valve)
TI N
1
RI C
A
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Charge the bucket with a load of approximate 1260 kg. Cut off the oil passage to the high-pressure side of the cylinder. Disconnect the Failure of boom cylinder cylinder from the main valve. Measure the displacement of piston for 15 minutes after the cylinder becomes stable. If the measured value is greater than 10 mm, it is deemed that cylinder has a defec-
Failure of boom valve Spool of boom valve may be worn excessively. Check the spool. spool
SA
NY
LA
Possible causes and standard value in normal state
Cause
7-106
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
Trouble (2) Related information
TI N
AM E
Malfunction or defective seal of 2 arm control valve (relief valve and makeup valve) Failure of arm 3 retaining valve Failure of arm 4 Arm valve (spool) may be worn excessively. Check it directly. valve (spool)
Trouble (3)
Related information
1
NY
Cause Failure of bucket cylinder
SA
Possible causes and standard value in normal state
A
Failure of arm cylinder
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Cut off the oil passage to the high-pressure side of the cylinder. Disconnect the cylinder from the main valve. Measure the displacement of piston for 15 minutes after the cylinder becomes stable. If the measured value is greater than 10 mm, it is deemed that cylinder has a defective seal. For more information on the measuring procedure refer to "Testing and Adjusting", "Hydraulic Drift (Work Equipment) - Test". Relief valve or makeup valve of the arm control valve may be defective. Check the valves directly. ● The performance of seal can be judged by replacing it with another relief valve or makeup valve. (Do not replace it with the boom-down relief valve or makeup valve as their pressures are set differently.) Arm retaining valve or pilot valve may be worn or sluggish. Check the valves.
RI C
1
Standard value in normal state/Remarks on troubleshooting
● The bucket drifts excessively. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
LA
Possible causes and standard value in normal state
Cause
● The arm drifts excessively. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
Standard value in normal state/Remarks on troubleshooting ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Bucket control lever Leakage from bucket cylinder
Bucket-in relief 20 ml/min Seal of relief valve or makeup valve of bucket control valve may be defecDefective seal tive. Check it directly. of bucket control 2 ● The performance of seal can be judged by replacing it with another valve (relief valve relief valve or makeup valve. (Do not replace it with the boom-down and makeup valve) relief valve or makeup valve as their pressures are set differently.) Defective seal 3 of bucket control Seal of bucket control valve spool may be defective. Check it directly. valve (spool)
Shop Manual - June 2013
7-107
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-11 Work equipment moves sluggishly Trouble
● Work equipment moves sluggishly. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
Cause
Standard value in normal state/Remarks on troubleshooting
Malfunction of arm Regeneration valve of arm may have malfunction. Check it directly. regeneration valve
2
Relief valve or makeup valve of control valve may have malfunction. Malfunction of Check it directly. control valve (relief ● For arm and boom, whether a valve has malfunction can be judged valve and makeup by replacing it with another relief valve or makeup valve. (Do not replace it with the boom-lower relief valve or makeup valve as valve) their pressures are set differently. )
AM E
RI C
A
1
TI N
Possible causes and standard value in normal state
Related information
H-12 Other work equipment moves while single oil circuit is relieved
7-108
Standard value in normal state/Remarks on troubleshooting
NY
Cause
SA
Possible causes and standard value in normal state
Related information
● Other work equipment moves while single oil circuit of certain work equipment is relieved. ● Set the working mode to (S) in order to perform troubleshooting.
LA
Trouble
1
Defective seal of control valve
Seal of control valve may be defective. Check it directly.
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-13 Travel speed drops considerably while swinging and travelling Trouble
● Travel speed drops considerably in swinging plus travelling operation. ● If the travel speed is low in only travelling operation, check first according to H-15. Standard value in normal state/Remarks on troubleshooting
Failure of straight travel valve
The straight travel valve gives no response. Check the spool and the logic oil circuit drain port.
AM E
1
RI C
A
Cause
SA
NY
LA
TI N
Possible causes and standard value in normal state
Related information
Shop Manual - June 2013
7-109
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-14 Machine deviates during travel Trouble
● Machine deviates during travel. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
Related information
Malfunction of pilot relief valve
A
2
RI C
Malfunction of travel pilot valve
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Travel control lever Pilot valve output pressure Forward 3.5~3.9 MPa Reverse { 36~40 kg/cm²} Difference occurs between 0.4 MPa {4 kg/cm²} left and right output ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Control lever Control circuit source pressure
AM E
1
All levers in "NEUTRAL"
6
7
TI N
5
Check the regulator by swapping the front and back regulators. ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Sluggishness of proportionTravel control lever Proportional valve output pressure al solenoid valve Operate both control levers ≤0.1 MPa Sluggishness of travel conCheck the valve spool to see whether it works well. trol valve (spool) Internal leakage of central Check it by swapping the lines. swivel joint ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Malfunction of travel motor Travel control lever Leakage of travel motor
LA
4
9
3.5~3.9 MPa { 36~40 kg/cm²}
Failure of regulator
NY
3
8
7-110
Standard value in normal state/Remarks on troubleshooting
Travel relief 27.2 ml/min Final drive may have internal defect. Check it directly. ● Internal defect of the final drive can be determined through Failure of final drive abnormal noise, abnormal heat, and metal powder or debris contained in the oil drained. ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Travel control lever Pilot valve output pressure Failure of travel pilot presForward 3.5~3.9MPa sure sensor Reverse { 36~40 kg/cm²} Difference occurs between 0.4 MPa {4 kg/cm²} left and right output Check the sensor by swapping it with another one.
SA
Possible causes and standard value in normal state
Cause
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-15 Travel speed is low Trouble Related information
A
Forward Reverse
3.5~3.9 MPa { 36~40 kg/cm²}
Difference occurs between left and ≤0.4 MPa right output ≤{4 kg/cm²} ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Malfunction of pilot Control lever Control circuit source pressure relief valve 3.5~3.9 MPa All levers in "NEUTRAL" { 36~40 kg/cm²}
AM E
2
Malfunction of travel pilot valve
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Travel control lever Pilot valve output pressure
Failure of sensor
Travel speed
Travel control lever
Reading on monitor
Lo
Operated
3.5~3.9 MPa { 36~40 kg/cm²}
LA
3
TI N
● Stop the engine. Perform troubleshooting while the engine is running at high idle.
4
Operated
Malfunction of travel Spool of travel control valve may have malfunction. Check it directly. control valve (spool) Malfunction of travel The makeup valve in travel control valve may have malfunction. Check control valve (makeit directly. up valve) Stop the engine. Perform troubleshooting while the engine is running at high idle. Failure of travel moTravel control lever Oil leakage of travel motor tor
SA
5
3.5~3.9 MPa { 36~40 kg/cm²} Check the sensor by replacing it with another one.
Hi
NY
Possible causes and standard value in normal state
1
Standard value in normal state/Remarks on troubleshooting
RI C
Cause
● Machine travel speed is low. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
6
7
Travel relief 27.2 ml/min Final drive may have internal defect. Check it directly. ● Internal defect of the final drive can be determined through abnorFailure of final drive mal noise, abnormal heat, and metal powder or debris contained in the oil drained.
Shop Manual - June 2013
7-111
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-16 Machine is not steered well or steering power is low Trouble
● Machine is not steered well or steering power is low ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
Related information
Cause
3.5~3.9 MPa { 36~40 kg/cm²} ● Stop the engine. Perform troubleshooting while the engine is running at high idle.
4
Both sides operated
3.5~3.9 MPa { 36~40 kg/cm²}
Either side operated
3.5~3.9 MPa { 36~40 kg/cm²}
Spool of travel control valve may have malfunction. Check it directly.
Malfunction of travel The makeup valve in travel control valve may have malfunction. control valve (makeup Check it directly. valve) Seal of relief valve in travel motor may be defective. Check it diFailure of travel motor rectly. (relief valve) ● The failure of seal can be determined by swapping the front and back motors or the left and right motors. Seal of check valve in travel motor may be defective. Check it diFailure of travel motor rectly. (check valve) ● The failure of seal can be determined by swapping the front and back motors or the left and right motors.
SA
6
Malfunction of travel control valve (spool)
Solenoid valve output pressure
TI N
3
Malfunction of travel pilot pressure sensor
Travel control lever
LA
2
AM E
Either side operated
5
7-112
RI C
A
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Travel control lever Pilot valve output pressure Malfunction of travel pilot valve Both sides in "NEUTRAL" 0 {0}
NY
Possible causes and standard value in normal state
1
Standard value in normal state/Remarks on troubleshooting
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-17 Travel speed cannot be changed Trouble
Cause
Standard value in normal state/Remarks on troubleshooting
2
AM E
1
RI C
A
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Solenoid valve output Malfunction of travel Travel speed Travel control lever pressure speed shifting solenoid Lo Operated 0 {0} valve 3.5~3.9 MPa Hi Operated { 36~40 kg/cm²} Failure of travel motor (in Speed shifting assembly of travel motor may have malfunction. speed change) Check it directly.
SA
NY
LA
TI N
Possible causes and standard value in normal state
Related information
● Travel speed cannot be changed. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
Shop Manual - June 2013
7-113
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-18 Travel system fails (only at one side) Trouble
● One side of the tracks cannot make a turn. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
Related information
Cause
Standard value in normal state/Remarks on troubleshooting
RI C
2
Defective seat of travel Seat of relief valve in travel control valve may have malfunction. motor (relief valve) Check it directly.
AM E
Defective seat of travel Seat of check valve in travel motor valve may have malfunction. 3 motor valve (makeup Check it directly. valve) ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Speed of travel motor 4 Travel control lever Leakage from travel motor drops.
Defective pilot pressure sensor
Forward Reverse
Difference occurs between left and right output Check it with swapping method.
SA
NY
6
TI N
5 Failure of final drive
Travel relief 27.2 ml/min Final drive may have internal defect. Check it directly. ● Internal defect of final drive can be determined with abnormal noise, overheat, and metal powder or debris contained in the oil drained. ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Travel control lever Pilot valve output pressure
LA
Possible causes and standard value in normal state
A
Defective seat of travel Seat of makeup valve in travel control valve may have malfunction. 1 control valve (makeup Check it directly. valve)
7-114
Shop Manual - June 2013
3.5~3.9MPa { 36~40 kg/cm²} 0.4 MPa {4 kg/cm²}
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-19 Swing operation fails Trouble (1) Related information
Malfunction of swing Parking brake of swing motor may have malfunction. Check it directly. motor (parking brake)
A
1
Standard value in normal state/Remarks on troubleshooting
Swing control lever Swing relief pressure Improper adjustment or malfunction of 25.5~28.5 MPa Swing relief swing motor (relief {260~291 kg/cm²} valve) If oil pressure does not become normal after adjustment, swing motor relief valve may have malfunction or internal defect. Check the relief
AM E
2
RI C
● Stop the engine. Perform troubleshooting while the engine is running at high idle.
4
Failure of swing mechanism
TI N
3
valve directly. ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Failure of swing motor Swing control lever Leakage from swing motor Swing relief ≥10 ml/min Swing mechanism may have internal defect. Check it directly. ● Internal defect of swing mechanism can be determined with abnormal noise, overheat, and metal powder or debris contained in the oil drained.
SA
NY
LA
Possible causes and standard value in normal state
Cause
● Upper structure fails to swing in either direction. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
Shop Manual - June 2013
7-115
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
Trouble (2)
● Upper structure only fails to swing in one direction. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
Cause
Standard value in normal state/Remarks on troubleshooting ● Stop the engine. Perform troubleshooting while the engine is running at high idle.
2
Malfunction of swing control valve (spool)
Left control lever
Pilot valve output pressure
"NEUTRAL"
0 {0}
Swing
≥3.5MPa {≥36 kg/cm²}
A
Malfunction of pilot valve
RI C
1
Spool of swing control valve may have malfunction. Check it directly.
AM E
Defective seal of Seal of makeup valve in swing motor may have defect. Check it directly. 3 swing motor (makeup ● Failure of the seal can be determined by swapping the right and left makeup valves and check for any changes. valve)
SA
NY
LA
TI N
Possible causes and standard value in normal state
Related information
7-116
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-20 Swing acceleration poor or swing speed low Trouble (1) Related information
Malfunction of swing Parking brake of swing motor may have malfunction. Check it directly. motor (parking brake)
A
1
Standard value in normal state/Remarks on troubleshooting
RI C
AM E
2
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Swing control lever Swing relief valve Improper adjustment or malfunction of 25.5~28.5 MPa Swing relief swing motor (relief {260~291 kg/cm²} valve) If oil pressure does not become normal after adjustment, swing motor
TI N
3
relief valve may have malfunction or internal defect. Check the relief valve directly. ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Failure of swing moSwing control lever Leakage from swing motor tor Swing relief
4
Clogging of brake control lines
≤10 ml/min
Disassemble, clean and check.
SA
NY
LA
Possible causes and standard value in normal state
Cause
● Swing acceleration is poor, or swing speed is low. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
Shop Manual - June 2013
7-117
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
● Swing acceleration is only poor on one side, or swing speed is low. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
Trouble (2) Related information
A
Malfunction of pilot valve
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Swing control lever Pilot valve output pressure "NEUTRAL" Left swing Right swing
0 {0}
RI C
1
Standard value in normal state/Remarks on troubleshooting
≥3.5MPa {≥36 kg/cm²}
TI N
AM E
Malfunction of swing Pressure compensation valve of swing motor may have malfunction. 2 motor (pressure comCheck it directly. pensation valve) Seal of makeup valve in swing motor may have defect. Check it diDefective seal of swing rectly. 3 motor (makeup valve) ● Swap the left and right makeup valves and observe the result in order to determine whether the seal fails. ● Stop the engine. Perform troubleshooting while the engine is running at high idle. One-side leakage of Swing control lever Pilot valve output pressure 4 swing pilot pressure "NEUTRAL" 0 {0} sensor (shuttle valve) Left swing 3.5~3.9MPa {36~40 kg/cm²} Right swing
SA
NY
LA
Possible causes and standard value in normal state
Cause
7-118
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-21 Upper structure overruns remarkably when it stops swinging ● Upper structure overruns remarkably when it stops swinging in both directions. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
Trouble (1)
Cause
Standard value in normal state/Remarks on troubleshooting
A
If oil pressure does not become normal after adjustment, swing motor
relief valve may have malfunction or internal defect. Check the relief valve directly. ● Stop the engine. Perform troubleshooting while the engine is running at high idle. Failure of swing motor Control lever Leakage from swing motor Swing relief
NY
Cause
≤10 ml/min
● Swing acceleration is only poor on one side, or swing speed is low. ● Set the working mode at gear (10) of power mode (S) to perform troubleshooting.
LA
Related information
1
25.5~28.5 MPa {260~291 kg/cm²}
AM E
2
Swing relief
RI C
Improper adjustment 1 or malfunction of swing motor (relief valve)
Trouble (2)
Malfunction of pilot valve
Standard value in normal state/Remarks on troubleshooting
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Swing control lever Pilot valve output pressure
"NEUTRAL" 0 {0} Left swing ≥3.5MPa {≥36 kg/cm²} Right swing Malfunction of swing con- Spool of swing control valve may have malfunction. Check it direct2 trol valve (spool) ly. Seal of makeup valve in swing motor may be defective. Check it Malfunction or defecdirectly. 3 tive seal of swing motor ● Swap the left and right makeup valves and observe the result (makeup valve) in order to determine whether the seal fails.
SA
Possible causes and standard value in normal state
● Stop the engine. Perform troubleshooting while the engine is running at high idle. Swing control lever Swing relief pressure
TI N
Possible causes and standard value in normal state
Related information
Shop Manual - June 2013
7-119
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-22 Large shock is produced when upper structure stops swinging Trouble
● Large shock is produced when upper structure stops swinging. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
Cause
Standard value in normal state/Remarks on troubleshooting
2
3
Swing control lever
Pilot valve output pressure
RI C
Malfunction of swing pilot valve
"NEUTRAL"
0 {0}
Left swing ≥3.5MPa {≥36 kg/cm²} Right swing Reverse prevention valve of swing motor may have malfunction. Malfunction of swing Check it directly. reverse prevention ● Replace the valve with a new on in order to determine whether the valve valve fails.
AM E
1
A
● Stop the engine. Perform troubleshooting while the engine is running at high idle.
Malfunction of swing relief valve
Swing relief valve may be worn or sluggish.
TI N
Possible causes and standard value in normal state
Related information
H-23 High noise is produced when upper structure stops swinging
7-120
NY
Cause
Malfunction of back pressure valve Malfunction of swing 2 motor (relief valve)
1
SA
Possible causes and standard value in normal state
Related information
● High noise is produced when upper structure stops swinging. ● Set working mode to (S) and fuel control dial at position (10) to carry out troubleshooting.
LA
Trouble
Standard value in normal state/Remarks on troubleshooting Back pressure valve may have malfunction. Check it directly. Relief valve of swing motor may have malfunction. Check it directly.
Seal of makeup valve in swing motor may have malfunction. Check it directly. ● Swap the left and right makeup valves and observe the result in order to determine whether the seal fails. The swing mechanism is suspected of an internal failure. Check the inside of the machinery itself. Failure of swing mecha4 ● Internal defect of swing mechanism can be determined with abnism normal noise, overheat, and metal powder or debris contained in the oil drained.
Malfunction of swing 3 motor (makeup valve)
Shop Manual - June 2013
Troubleshooting
SY195/205/215/225C9 Crawler Hydraulic Excavator
H-24 Swing drift excessive Trouble (1)
Standard value in normal state/Remarks on troubleshooting
RI C
A
Cause
Failure of swing hold- Swing holding brake control lines and holding brake pilot valve may be ing brake control lines defective. Check them directly.
2
Malfunction of swing Parking brake of swing motor may have malfunction. Check it directly. motor (parking brake)
AM E
1
TI N
Possible causes and standard value in normal state
Related information
● Hydraulic drift of swing is large (when swing holding brake is applied). ● When swing lock switch is turned ON or when swing holding brake release switch is in normal position, swing holding brake operates and upper structure is fixed with disc brake.
● Hydraulic drift of swing is large (when swing holding brake is released). ● When swing holding brake release switch is in release position, swing holding brake is released and upper structure is secured by only hydraulic pressure.
LA
Trouble (2)
NY
Cause Malfunction or defec1 tive seal of swing control valve (spool)
Standard value in normal state/Remarks on troubleshooting Swing control valve spool may have malfunction or defective seal. Check it directly.
SA
Possible causes and standard value in normal state
Related information
2
Failure of swing motor Seal of relief valve in swing motor may be defective. Check it directly. (relief valve)
3
Failure of swing motor Seal of makeup valve in swing motor may be defective. Check it di(makeup valve) rectly.
Shop Manual - June 2013
7-121
SY195/205/215/225C9 Crawler Hydraulic Excavator
BSLAN AYNL AT K IN PAA M GERI E CA
Troubleshooting
7-122
Shop Manual - June 2013
Disassembly and Assembly
A
SY195/205/215/225C9 Crawler Hydraulic Excavator
RI C
Disassembly and Assembly 8 Disassembly and Assembly
SA
NY
LA
TI N
AM E
8.1 How to Read This Manual ....................................................................................... 8-5 8.1.1 Removing and Installing an Assembly ........................................................... 8-5 8.1.2 Disassembling and assembling an assembly ................................................ 8-5 8.1.3 Special tools................................................................................................... 8-5 8.2.1 The symbols used in this section .................................................................. 8-6 8.2 Operating Precautions ............................................................................................. 8-6 8.3 Start Motor AS - Remove and Install ..................................................................... 8-10 8.3.1 Removal ....................................................................................................... 8-10 8.3.2 Installation .................................................................................................... 8-10 8.4 Injection Pump AS - Remove and Install ................................................................8-11 8.4.1 Removal ........................................................................................................8-11 8.4.2 Installation .................................................................................................... 8-13 8.5 Engine Front Seal - Remove and Install ................................................................ 8-15 8.5.1 Removal ....................................................................................................... 8-15 8.5.2 Installation .................................................................................................... 8-15 8.6 Engine Rear Seal - Remove and Install................................................................. 8-16 8.6.1 Removal ....................................................................................................... 8-16 8.6.2 Installation .................................................................................................... 8-17 8.7 Cylinder Head AS - Remove and Install ................................................................ 8-18 8.7.1 Removal ....................................................................................................... 8-18 8.7.2 Installation .................................................................................................... 8-22 8.8 Radiator AS - Remove and Install.......................................................................... 8-24 8.8.1 Removal ....................................................................................................... 8-24 8.8.2 Installation .................................................................................................... 8-27 8.9 Engine and Hydraulic Pump AS - Remove and Install .......................................... 8-28 8.9.1 Removal ....................................................................................................... 8-28 Shop Manual - June 2013
8-1
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
SA
NY
LA
TI N
AM E
RI C
A
8.9.2 Installation .................................................................................................... 8-34 8.10 Final Drive AS - Remove and Install .................................................................... 8-35 8.10.1 Removal ..................................................................................................... 8-35 8.10.2 Installation .................................................................................................. 8-36 8.11 Final Drive AS - Disassemble and Assemble ....................................................... 8-37 8.11.1 Disassembly ............................................................................................... 8-37 8.11.2 Assembly .................................................................................................... 8-41 8.12 Swing Motor and Swing Drive AS - Remove and Install ...................................... 8-46 8.12.1 Removal ..................................................................................................... 8-46 8.12.2 Installation .................................................................................................. 8-47 8.13 Swing Motor and Swing Drive AS - Disassemble and Assemble......................... 8-48 8.13.1 Disassembly............................................................................................... 8-48 8.13.2 Assembly.................................................................................................... 8-53 8.14 Idler AS - Disassemble and Assemble ................................................................. 8-58 8.14.1 Disassembly............................................................................................... 8-58 8.14.2 Assembly.................................................................................................... 8-59 8.15 Sprocket - Remove and Install............................................................................. 8-62 8.15.1 Removal ..................................................................................................... 8-62 8.15.2 Installation .................................................................................................. 8-62 8.16 Track AS - Remove and Install ............................................................................ 8-63 8.16.1 Removal ..................................................................................................... 8-63 8.16.2 Installation .................................................................................................. 8-65 8.17 Swing Bearing AS - Remove and Install .............................................................. 8-66 8.17.1 Removal ..................................................................................................... 8-66 8.17.2 Installation .................................................................................................. 8-67 8.18 Swing Platform AS - Remove and Install ............................................................. 8-68 8.18.1 Removal ..................................................................................................... 8-68 8.18.2 Installation .................................................................................................. 8-71 8.19 Swivel Joint AS - Remove and Install .................................................................. 8-72 8.19.1 Removal ..................................................................................................... 8-72 8.19.2 Installation .................................................................................................. 8-74 8.20 Swivel Joint AS - Disassemble and Assemble ..................................................... 8-75 8.20.1 Disassembly............................................................................................... 8-75 8.20.2 Assembly.................................................................................................... 8-76 8.21 Hydraulic Tank AS - Remove and Install.............................................................. 8-77 8.21.1 Removal ..................................................................................................... 8-77 8.21.2 Installation .................................................................................................. 8-79 8.22 Control Valve AS - Remove and Install ................................................................ 8-80
8-2
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
SA
NY
LA
TI N
AM E
RI C
A
8.22.1 Removal ..................................................................................................... 8-80 8.22.2 Installation .................................................................................................. 8-84 8.23 Hydraulic Pump AS - Remove and Install ............................................................ 8-85 8.23.1 Removal ..................................................................................................... 8-85 8.23.2 Installation .................................................................................................. 8-89 8.24 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install .................... 8-90 8.24.1 Removal ..................................................................................................... 8-90 8.24.2 Installation .................................................................................................. 8-90 8.25 Pilot Valve AS (Work Equipment) - Disassemble and Assemble ......................... 8-91 8.25.1 Assembly.................................................................................................... 8-91 8.26 Pilot Valve AS (Travel) - Disassemble and Assemble .......................................... 8-93 8.26.1 Assembly.................................................................................................... 8-93 8.27 Hydraulic Cylinder AS - Disassemble and Assemble........................................... 8-94 8.27.1 Disassembly............................................................................................... 8-95 8.27.2 Assembly.................................................................................................. 8-100 8.28 Work Equipment AS - Remove and Install......................................................... 8-105 8.28.1 Removal ................................................................................................... 8-105 8.28.2 Installation ................................................................................................ 8-107 8.29 Air Conditioner AS - Remove and Install............................................................ 8-108 8.29.1 Removal ................................................................................................... 8-108 8.29.2 Installation .................................................................................................8-112 8.30 Counterweight AS - Remove and Install .............................................................8-113 8.30.1 Removal ....................................................................................................8-113 8.30.2 Installation .................................................................................................8-114 8.31 Cab AS - Remove and Install..............................................................................8-115 8.31.1 Removal ....................................................................................................8-115 8.31.2 Installation .................................................................................................8-119 8.32 Cab Window Glass – Disassemble and Assemble ............................................ 8-120 8.32.1 Removal ................................................................................................... 8-121 8.32.2 Installation ................................................................................................ 8-125 8.33 Front Window AS - Disassemble and Assemble................................................ 8-138 8.33.1 Disassemble ............................................................................................ 8-138 8.33.2 Assemble ................................................................................................. 8-141 8.34 Monitor - Remove and Install ............................................................................. 8-146 8.34.1 Removal ................................................................................................... 8-146 8.34.2 Installation ................................................................................................ 8-146 8.35 Controller AS - Remove and Install.................................................................... 8-147 8.35.1 Removal ................................................................................................... 8-147
Shop Manual - June 2013
8-3
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
SA
NY
LA
TI N
AM E
RI C
A
8.35.2 Installation ................................................................................................ 8-147 8.36 Radio ................................................................................................................. 8-148 8.36.1 Structure .................................................................................................. 8-148 8.36.2 Removal ................................................................................................... 8-149 8.36.3 Installation ................................................................................................ 8-150 8.36.4 Connector model and wiring .................................................................... 8-150 8.37 Battery ............................................................................................................... 8-151 8.37.1 Structure .................................................................................................. 8-151 8.37.2 Removal ................................................................................................... 8-152 8.37.3 Installation ................................................................................................ 8-153 8.37.4 Replacement ............................................................................................ 8-153 8.38 Start Switch........................................................................................................ 8-154 8.38.1 Structure ................................................................................................. 8-154 8.38.2 Removal ................................................................................................... 8-155 8.39 Fuse Box............................................................................................................ 8-157 8.39.1 Removal ................................................................................................... 8-157 8.40 Wiper ................................................................................................................. 8-158 8.40.1 Structure .................................................................................................. 8-158 8.40.2 Working principle ..................................................................................... 8-158 8.40.3 Removal ................................................................................................... 8-159 8.40.5 Installation ................................................................................................ 8-160 8.40.4 Angle adjustment of wiper arm................................................................. 8-160 8.41 Relay.................................................................................................................. 8-161 8.41.1 Engine relays ........................................................................................... 8-161 8.41.2 Other relays ............................................................................................. 8-162 8.42 Sensor ............................................................................................................... 8-165 8.43 Connector Terminals - Insert and Remove ........................................................ 8-167 8.43.1 Insertion ................................................................................................... 8-167 8.43.2 Removal ................................................................................................... 8-168
8-4
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8 DISASSEMBLY AND ASSEMBLY 8.1 How to Read This Manual 8.1.1 Removing and Installing an Assembly Removal
RI C
A
● The "Removal" section contains procedure, precautions and the amount of oil or water to be discharged. Installation
AM E
● Unless specified otherwise, installation of a part is a reverse procedure of removing the part.
8.1.2 Disassembling and assembling an assembly Disassembly
TI N
● The "Disassembly" section contains procedure, precautions and the amount of oil or water to be discharged. Assembly
LA
● The "Assembly " section contains operating procedure, precautions, technical specification and the amount of oil or water to be added.
NY
8.1.3 Special tools ● Special tools for parts disassembly and assembly are listed.
SA
● Necessary characteristics of the tools are noted in the list of special tools. ■: Special tools that cannot be replaced and must be used. ●: Very useful tools, which can be replaced with commercially available ones.
Shop Manual - June 2013
8-5
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.1.4 The symbols used in this section This section uses some symbols and icons that are not used elsewhere in this manual. They include: This symbol indicates the amount of oil or water to be discharged. This symbol indicates that specific coating agent must be used. This symbol indicates the lubricant required.
RI C
A
This symbol indicates a torque specified. This symbol indicates the amount of oil or water to be added.
AM E
This symbols indicates the weight of a component or an assembly.
8.2 Operating Precautions
The following precautions must be observed before removing or installing (disassembling or assembling) a component.
TI N
1. Precautions to be observed prior to removal operation ● Dispose the engine coolant properly if antifreeze is contained in the engine coolant.
LA
● After disconnecting a hose or tube, cover or plug must be used to prevent invasion of dirt or dust. ● A suitable container must be prepared to collect oil when draining the oil. ● Matching mark must be made at where is necessary before removing in order to avoid mistake during reinstallation.
NY
● Do not pull the wire and avoid the wire coming off. To avoid excessive force imposing on the wire, hold the connector when disconnecting a wire.
SA
● Tag the wires and the hoses in order to ensure their connecting positions. By doing so, mistakes can be avoided during reinstallation. ● Count and check the number and thickness of the shims, and keep them in a safe place. ● When raising or lifting components, be sure to use proper lifting equipment of ample strength and safety. ● When forcing screws are used to remove any components, tighten the screws evenly in turn. ● The surrounding area must be cleaned before removing a unit. Cover the unit after removal in order to prevent invasion of dirt or dust.
8-6
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
● Precautions to be observed when disassembling the lines The lines disassembled must be blinded with plugs. A: Thread-connected hoses I.D. (mm)
Code
Description
B210780001189
Plug
8
B210780001190
Plug
10
B210780000077
Plug
12
B210780000078
15
B210780000883
20
B210780000079
22
60056667
RI C
6
A
Light Thread Connection
Plug Plug
AM E
Plug
Plug
Heavy Thread Connection B210780001142
16
60002397
20
B210780000080
Plug
25
B210780000081
Plug
TI N
12
Plug Plug
B: Thread-connected adaptors (plug and nut used in combination) Code
Description
LA
I.D. (mm)
Code
Description
Light Thread Connection
B210780000903
Taper bore plug
23002925
Nut
8
B210780001146
Plug
B210770000011
Nut
10
B210780000088
Plug
B210334000011
Nut
B210780000089
Plug
B210334000012
Nut
B210780000882
Plug
B210334000004
Nut
20
B210780000090
Plug
B210334000010
Nut
22
B210780000091
Plug
B210780000112
Nut
12
SA
15
NY
6
Heavy Thread Connection
12
B210780001143
Plug
B210780000406
Nut
16
A820205001523
Plug
B210780000405
Nut
20
B210780000902
Plug
B210780000904
Nut
25
B210780001172
Plug
B210334000006
Nut
Shop Manual - June 2013
8-7
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
2. Precautions prior to installation operation ● Tighten all the screws and nuts (sleeve nuts) to specified torques. ● Install the hoses without twisting or interference. ● Replace the gaskets, O-rings, cotter pins and lock plates with new parts. ● Bend the cotter pin or lock plate securely.
A
● Before applying the adhesive, clean the parts of oil and dust. Apply 2 or 3 drops of adhesive to the threaded portion.
RI C
● Before applying the sealant to the gasket, clean the gasket surface of oil and dust. Check the gasket for contamination or damage. Apply the gasket sealant evenly.
● Apply engine oil to the moving parts.
AM E
● Clean all parts, and correct any damage, dents, burrs, or rust.
● Before installing a snap ring, make sure that the snap ring is mounted properly in the circular groove.
TI N
● Before connecting the wiring connector, clean the wiring connector of oil, dirt or water. Make sure that the wiring connector is connected securely. ● Before using an eyebolt, check the eyebolt for deformation or deterioration. Screw on the eyebolt as far as possible and align it to the direction of the hook.
LA
● Before tightening the split flange, tighten it evenly in turn in order to prevent over tightening on one side.
NY
NOTE: After reassembling the hydraulic cylinder, main pump or other hydraulic equipment that has been disassembled and repaired, it is necessary to bleed the air from the hydraulic cylinder prior to initial operation of the cylinder. The purging procedure is performed as the following: 1) Start the engine and run the engine at low idle.
SA
2) Operate the work equipment control lever in order to cycle the movement of the hydraulic cylinder 4 or 5 times. Hold the cylinder at where it is 100 mm from its stroke end. 3) Go on operating the hydraulic cylinder 3 or 4 times to its stroke end. 4) You can run the engine at normal speed after this operation. NOTE: This procedure is to be performed before using your machine for the first time after repair or long storage.
8-8
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
3. Precautions to be observed upon completion of the operations ● Completely discharge the engine coolant, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Check the coolant level again. ● Add hydraulic oil to the specified level after disassembly and reinstallation of a hydraulic unit. Run the engine to circulate the hydraulic oil through the system. Check the oil level again.
RI C
A
● Bleed the air from the system after removing and repairing the lines or hydraulic unit and reassembling the parts. For more information, see “Air in Each Component - Bleed” on page 6-46.
SA
NY
LA
TI N
AM E
● Add the specified amount of grease (molybdenum disulphide) to the work equipment related parts.
Shop Manual - June 2013
8-9
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.3 Start Motor AS - Remove and Install 8.3.1 Removal CAUTION
RI C
A
● Before removing the start motor assembly, disconnect the cable from the negative (-) post of the battery, and insulate between the cable and the negative post with insulation tape.
2. Disconnect the cables (1), (2), (3), (4) and (5).
Starter
Terminal B
TI N
3. Unscrew the bolts (6) and (7) used to fix the start motor. Remove the start motor assembly.
AM E
1. Open the engine hood.
NY
LA
Terminal S
Starter relay ZX215-1006001
8.3.2 Installation
1
2
3
4
6
SA
● Installation is to be performed in the reverse order of removal. Terminal B locknut (start motor): 18 ~ 25 N·m {1.8 ~ 2.6 kgf·m} Fixing bolts (start motor): 43±6 N·m {4.4±0.6 kgf·m}
5 7 ZX215T-1006002
8-10
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.4 Injection Pump AS - Remove and Install 8.4.1 Removal CAUTION
A
● Disconnect the negative (-) post of the battery.
ZX215T-1006003
1
LA
TI N
2. Disconnect the air intake hose (1).
AM E
RI C
1. Open the engine hood.
SA
NY
ZX215T-1006004
3. Disconnect fuel supply tube (2), fuel delivery hose (4), fuel return hose (3) and fuel supply tube (5).
5
● Block the hose with a cork in order to prevent flow of fuel from the hose. 3 2
4
Shop Manual - June 2013
ZX215T-1006005
8-11
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
4. Disconnect the lubrication tube (6).
RI C
A
6
ZX215T-1006006
5. Disconnect six fuel delivery tubes (7).
ZX215T-1006007
LA
TI N
AM E
7
6. Disconnect the air hose (8).
7. Remove the bolt (9) fixing the electronic choke. Disconnect the bolt (10) fixing the governor motor.
SA
NY
8
9
10 ZX215T-1006008
8-12
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8. Adjust the injection timing of the timing gear. For more information, see “Fuel Injection Timing - Test and Adjust” on page 6-13. 9. Remove the injection pump mounting nuts in order to disassemble the injection pump assembly. B
A: 4 nuts on the flange
8.4.2 Installation ● Installation is to be performed in the reverse order of removal.
TI N
Bolts for installation of fuel supply tube:
ZX215-1006009
AM E
RI C
A
A
B: 1 nut
20~29 N·m {2.1~3.0 kgf·m} Relief valve:
LA
20~29 N·m {2.1~3.0 kgf·m} Bolts for installation of engine oil line: 10~13 N·m {1.0~1.3 kgf·m}
NY
Fuel injection tube: 24 N·m {2.5 kgf·m}
SA
Bolts for installation air hose: 12~15 N·m {1.2~1.5 kgf·m}
● Adjust the engine speed. For more information, see “Engine Speed - Test and Calibrate” on page 6-3.
Shop Manual - June 2013
8-13
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
● Installation of the fuel injection pump is to be performed as the following: 1) Check the fuel injection timing to see if it has been adjusted properly. ● For more information, see “Fuel Injection Timing - Test and Adjust” on page 6-13.
Nut: 9.8±2 N·m {10±0.2 kgf·m}
A
● Air bleeding
AM E
LA NY SA 8-14
B
ZX215-1006009
TI N
Bleed the air from the fuel injection system.
RI C
A
2) Assemble the fuel injection pump assembly and tighten the 4 nuts at position A and 1 nut at position B.
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.5 Engine Front Seal - Remove and Install 8.5.1 Removal 1. Remove the radiator assembly. For more information, see “Radiator AS Remove and Install” on page 8-24.
A
Water pump
2. Remove the engine fan (1), the belt (2) and the pulley (3).
3
2 ZX215-1006010
6
Ta 4 7 5
ZX215-1006011
NY
LA
TI N
3. Remove the mounting nut (4) and replace the cone (5) and the O-ring (6). Remove the crankshaft belt pulley (7).
AM E
RI C
1
SA
4. Disassemble the front oil seal (8).
8.5.2 Installation ● Installation is to be performed in the reverse order of removal.
8
Nut: 490 N·m {50 kgf·m}
Shop Manual - June 2013
ZX215-1006012
8-15
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.6 Engine Rear Seal - Remove and Install 8.6.1 Removal 1. Remove the hydraulic pump assembly. For more information, see “Hydraulic Pump AS - Remove and Install” on page 8-85.
3. Remove the flywheel (4). 4. Remove the engine speed sensor (5) and the flywheel shell (6).
3
RI C
A
2. Remove the bolt (1), the latch piece (2) and the bearing (3).
6
Ta 1
4
AM E
2
ZX215-1006013
LA
TI N
5. Remove the rear seal (7).
5
Lip
7
SA
NY
ZX215-1006014
8-16
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.6.2 Installation ● The installation is to be performed in the reverse order of removal. Bolt: 39 N·m {4.0 kgf·m} + 47°
Sealant
1. Apply engine oil to the lips of the rear seal. 2. Clean the oil-sealing surface. 3. Apply the sealant evenly and continuously align the line of the rear seal.
ZX215-1006015
SA
NY
LA
TI N
4. The installation is to be performed 3 minutes after application of the sealant. Be careful not to deviate the line while applying the sealant.
ø2mm
AM E
Sealant (Tonsun 1596)
Line
RI C
A
● The rear oil seal is to be installed according to the following procedure:
Shop Manual - June 2013
8-17
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.7 Cylinder Head AS - Remove and Install 8.7.1 Removal CAUTION
A
● Disconnect the negative (-) post of the battery.
RI C
1. Drain the engine of coolant. Coolant: 18 L
AM E
2. Open the engine hood.
1
LA
TI N
3. Disconnect the air intake hose (1).
ZX215T-1006016
NY
ZX215T-1006017
SA
4. Remove piping (2) and piping (3) between the fuel filter and the injection pump.
3 2 ZX215T-1006018
8-18
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
5. Remove the fuel filter bracket (4) and the fuel filter assembly (5). 6. Remove the six delivery hoses (6).
4
AM E
LA
ZX215T-1006020
8. Remove the air cleaner suction hose (8).
NY
9. Remove the air intake tube (9) and its clamps (10) between the turbocharger and the intercooler.
ZX215T-1006019
6
TI N
7. Remove the exhaust muffler connector cover (7).
RI C
A
5
9 10
7
SA
10. Remove the engine oil delivery tube (11) and the oil return tube (12).
8
Shop Manual - June 2013
ZX215T-1006021
8-19
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
11. Remove the turbocharger assembly.
A
11
RI C
12
ZX215-1006022
AM E
13
TI N
12. Remove the exhaust manifold (13).
LA
ZX215-1006023
14
SA
NY
13. Remove the radiator inlet hose (14) and outlet hose (15).
15 ZX215T-1006024
8-20
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
14. Remove the six nozzle seats (16).
RI C
A
16
16. Remove the rocker arm assembly (18). 17. Remove the pushrod (19).
TI N
18. Remove the 25 mounting bolts from the cylinder head assembly. Lift the cylinder head assembly in order to disassemble it.
AM E
15. Remove the rocker arm housing (17).
17
18
19 20
LA
19. Remove the cylinder head gasket (21).
ZX215T-1006025
SA
NY
21
ZX215-1006026
Shop Manual - June 2013
8-21
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.7.2 Installation ● The installation is to be performed in the reverse order of removal. Installation of cylinder head gasket
A
Choose a cylinder head gasket as per the following.
Unit: mm Cylinder Head Gasket
TI N
Piston Projection
AM E
2. Select from the following table a gasket with a thickness suitable for the maximum piston projection after measurement. In addition, even if one cylinder's piston projection is 0.05 mm greater than the average, the gasket with a thickness one grader higher (A→B, B→C) is to be used.
RI C
1. Measure the amount of piston projection of each cylinder.
Size
0.546~0.610
A
Thickness Tightened 1.3
0.610~0.674
B
1.35
0.674~0.738
C
LA
Average
A
Size mark B
C
1.4
“UP”
NY
3. The size of cylinder head gasket is determined according the notch.
SA
4. Install the cylinder head gasket to the crankshaft case as indicated by the arrow.
Notch
NOTICE
ZX215-1006027
The amount of piston projection must be measured as the amount of piston projection may vary when replacing a piston or connecting rod.
8-22
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
Bolt (rocker cover installation): 4.9~6.9 N·m {0.5~0.7 kgf·m} Bolt (cylinder head): 147 N·m {15 kgf·m}+90° Bolt threads (cylinder head):
A
Engine oil
RI C
Tappet circumference: Engine oil Tappet ends:
● Adjustment of valve clearance F o r m o r e i n f o r m a t i o n , s e e “ Va l v e Clearance - Adjust” on page 6-8.
AM E
Engine oil
TI N
● Adding coolant
SA
NY
LA
Add engine coolant to the specified level. Start the engine to circulate the coolant in order to release all foams. Check the coolant level again.
Shop Manual - June 2013
8-23
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.8 Radiator AS - Remove and Install 8.8.1 Removal 1. Open the engine hood.
A
2. Open the pressure cap (1). Open the drain valve to discharge engine coolant from the coolant tank. Coolant: approx. 18 L
RI C
1 Cover plate
4. Remove the two U-bolts (2).
ZX215T-1006028
TI N
5. Disconnect the hydraulic oil cooler inlet connector (3) and outlet connector (4). Block the openings to prevent leakage of hydraulic oil.
AM E
3. Remove the coverplate.
3
LA
6. Discharge hydraulic oil from the hydraulic cooler. Hydraulic oil radiator: approx. 5.6 L 7. Disconnect the coolant tank hose (5).
4
2
NY
ZX215T-1006029
SA
8. Disconnect the cooler inlet hose (6) and outlet hose (7).
5
ZX215T-1006030
8-24
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
9. Disconnect the intercooler air inlet tube (8) and outlet tube (9).
6
8
RI C
ZX215T-1006031
10
10
TI N
10. Remove the four bolts (10) from the air conditioner radiator. Remove the air conditioner radiator and store it properly.
AM E
7
A
9
LA
ZX215T-1006032
SA
NY
11. Remove the radiator fan guard (11).
11
ZX215T-1006033
Shop Manual - June 2013
8-25
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
12. Remove the four mounting bolts (12) from the radiator bottom and the two mounting bolts (13) from the left and right brackets.
A
13
SA
NY
LA
TI N
NOTE: Before the radiator assembly is hoisted, move the radiator assembly axially until the fan avoids its guard.
8-26
ZX215T-1006034
AM E
13. Mount the hoisting bolts (14) to both sides of the radiator in order to hoist the radiator assembly.
RI C
12
Shop Manual - June 2013
14
ZXT335-1006029
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.8.2 Installation ● Installation is to be performed in the reverse order of removal. NOTE:
A
● Adjust the clearance (a) between the fan and the fan guard in order to have a uniform clearance surrounding the fan.
RI C
● Check the values (a) at the four measuring points in the left, right, top and bottom directions, which should be as the following:
Fan diameter (b): ø620 mm Fan guard inner diameter (c): ø650 mm ● Engine coolant and hydraulic oil adding
AM E
Standard clearance (a) in all directions: 15±1.5 mm
TI N
Add a specific amount of coolant and hydraulic oil. Start the engine to circulate the coolant and hydraulic oil. Check the coolant level and the oil level.
LA
Engine coolant: approx. 18 L
SA
NY
Hydraulic oil radiator: approx. 12 L
Shop Manual - June 2013
8-27
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.9 Engine and Hydraulic Pump AS - Remove and Install 8.9.1 Removal CAUTION
RI C
A
● Lower the work equipment to the ground. Stop the engine. Disconnect the cable from the battery negative (-) post.
NOTE: Mark the lines to avoid mistakes during reinstallation. 1. Remove the hydraulic tank suction filter element and block the opening.
AM E
● Loosen the butterfly nut on the breather valve and press the relief button to relieve internal pressure.
TI N
2. Drain the engine of coolant. Coolant: approx. 18 L
LA
3. Open the engine hood.
NY
ZX215T-1006028
SA
4. Disconnect piping (1), (2) and (3).
2
3
1 ZX215T-1006036
8-28
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
5. Disconnect piping (4), (5) and (6). 5
6. Remove the sensors (7) and (8).
6 4
A
7
AM E
7. Remove the clamps (9) and (10). Remove the line (11) and the cable (12).
RI C
8
ZX215T-1006037
11
10
LA
TI N
9
12
NY
ZX215T-1006038
SA
8. Unscrew the connection bolt (13) of the governor motor and the connection bolt (14) of the engine stopper. 9. Disconnect the external cable from the starter (15). 10. Remove the mounting bolt (16) from the hose clamp.
15 14 13
16 ZX215T-1006039
Shop Manual - June 2013
8-29
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
11. Disconnect the cables (17) and (18) as well as the tubes (19) and (20) from the compressor.
18
20
17
RI C
A
19
12. Disconnect the hoses (21), (22), (23) and (24) between the engine and the radiator
AM E
ZX215T-1006040
24
TI N
21
22 23
LA
ZX215T-1006041
SA
NY
13. Disconnect the air intake hose (25).
25 ZX215T-1006042
8-30
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
14. Disconnect the external cable (26) of the rpm sensor. 15. Disconnect the external cable (27) of engine oil pressure sensor.
27
17. Disconnect the wiring (30) of the engine oil pressure switch.
AM E
16. Disconnect the engine oil inlet tube (28) and outlet tube (29).
RI C
A
26
ZX215T-1006043
30
29
TI N
28
LA
ZX215T-1006044
NY
18. Disconnect the cables (31) and (32), and remove the hose clamp (33).
SA
33
32 31 ZX215T-1006045
Shop Manual - June 2013
8-31
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
19. Remove the hose clamp (35). 20. Disconnect the wiring (34) of the water temperature sensor. 35
RI C
A
34
TI N
21. Disconnect the cables (36) and (37) of the water temperature switch.
AM E
ZX215T-1006046
37
36
LA
ZX215T-1006047
22. Disconnect the oil return hose (38).
38
SA
NY
23. Disconnect the A/C water pipe (39).
39 ZX215T-1006048
8-32
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
24. Disconnect the radiator fan guard (40).
Engine and hydraulic pump AS:
41 41 ZX215T-1006050
SA
NY
LA
TI N
640 kg
ZX215T-1006049
AM E
25. Remove the fixing bolt (41) on each of the four mounting plates of the damper. Lift the engine and main pump assembly.
RI C
A
40
Shop Manual - June 2013
8-33
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.9.2 Installation ● Installation is to be performed in the reverse order of removal. ● Open the radiator tank cover to add coolant. Also add coolant to the coolant reservoir.
A
Engine coolant: approx. 22.5 L.
RI C
● Refill the hydraulic tank with hydraulic oil.
● Start the engine to circulate the coolant in order release the foams, and check the coolant level again.
TI N
● Start the engine to circulate the hydraulic oil in the hydraulic system, and check the oil level again.
AM E
Hydraulic tank: approx. 225 L
● Air bleeding
SA
NY
LA
For more information, see “Air in Each Component - Bleed” on page 6-46.
8-34
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.10 Final Drive AS - Remove and Install 8.10.1 Removal CAUTION
RI C
A
● Lower the work equipment to the ground. Stop the engine. Operate the breather valve to release internal pressure.
For more information, see “Sprocket Remove and Install” on page 8-62.
LA
TI N
2. Remove the motor cover plate (1).
AM E
1. Remove the sprocket.
ZX215-1006051
2
SA
NY
3. Disconnect the four hoses (2) of the travel motor and the corresponding hose connectors.
1
ZX215T-1006052
Shop Manual - June 2013
8-35
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
4. Remove the 30 mounting bolts from the final drive assembly (3), and lift the assembly for disassembling. 3
Final Drive Assembly: 250 kg
NOTICE
RI C
A
● Be careful not to damage the surface of mounting seal installed on the hose base.
ZX215-1006053
8.10.2 Installation ● Installation is to be performed in the reverse order of removal.
AM E
● Never use the threaded holes to lift the cover when lifting the final drive.
TI N
Mounting bolts (final drive assembly):
● Hydraulic oil adding
LA
245~309 N·m {25~31 kgf·m}
● Air bleeding
NY
Add hydraulic oil through the filler opening to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again.
SA
For more information, see “Air in Each Component - Bleed” on page 6-46.
8-36
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.11 Final Drive AS - Disassemble and Assemble 8.11.1 Disassembly 1. Oil draining Open the drain plug to drain the oil from the final drive tank.
A
Final drive tank: approx. 4.7 L
to the
①
AM E
Remove the bolts. Use eyebolts cover (1).
RI C
2. Cover
TI N
1
LA
3. Spacer
ZX215-1006054
2
SA
NY
Remove the spacer (2).
ZX215-1006055
Shop Manual - June 2013
8-37
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
4. No. 1 planetary carrier assembly 3
A
1) Remove the No.1 planetary carrier assembly (3).
2) Disassembly of No.1 planetary carrier assembly. 3) Remove the screws (4). Remove the coverplate (5) from the planetary carrier assembly (6).
7
TI N
4) Remove the thrust washer (7), gear (8), bearing (9), bearing inner race (10) and a second thrust washer (11).
9
AM E
RI C
ZX215-1006056
LA
5. No.1 sun gear shaft
11
5
4
10
8
6 ZX215-1006057
12
SA
NY
Remove No.1 sun gear shaft (12).
ZX215-1006058
8-38
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
6. Thrust washer
13
14
Remove the thrust washer (13). 7. No.2 sun gear
1) Remove the screws (15). Remove the plate (16) and the planetary gear (17) from the carrier assembly (22).
TI N
2) Remove the bearing inner race (19) and outer race (18). Remove the plate (20).
AM E
8. Disassembly of No.2 planetary carrier assembly
RI C
A
Remove No.2 sun gear (14).
18
19
ZX215-1006059
15 16
17
20
23
21 22
3) Remove the screw (21) to take the planetary carrier assembly (22) and the shim (23) from the body.
LA
ZX215-1006060
9. Hub assembly
NY
②
SA
1) Use eyebolts to remove the hub assembly (24) from the travel motor.
24
ZX215-1006061
Shop Manual - June 2013
8-39
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
2) Disassemble the hub assembly as the following.
27
26
3) Remove the float seal (25). 4) Remove the bearing (26) and bearing (27) from the hub (28).
A
NOTE: Do not damage the bearing retainer when removing the bearing (26). 25
28
RI C
ZX215-1006062
AM E
5) Remove the float seal (29) from the travel motor.
30
SA
NY
LA
TI N
29
8-40
Shop Manual - June 2013
ZX215-1006063
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.11.2 Assembly NOTE: Clean all the parts. Check that these parts are free from any contamination or damage. Apply some engine oil to the sliding surface prior to installation.
1) Install the bearing 26 and bearing (27) by pressing them onto the hub (28).
A
1. Hub assembly
26
AM E
RI C
2) Install the float seal (25).
27
25
28 ZX215-1006062
TI N
● Remove any oil or dust from the O-ring or O-ring contact surface. Dry the parts before installing the float seal.
LA
● After installing the float seal, check that the angle of the floating seal is within 1 mm.
NY
● Apply a thin layer of engine oil to the sliding surface after the float seal has been installed.
SA
ZX215-1006064
3) Install the float seal (29) to the travel motor (30). ● See the above step 2 for the installation procedure.
29
30 ZX215-1006063
Shop Manual - June 2013
8-41
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
4) Use eyebolts to carefully place the hub assembly (24) onto the travel motor. Tap to press fit the bearing.
②
RI C
A
24
ZX215-1006061
AM E
2. Calculation of shim thickness 1) Measure the thickness (H) of the raised part of No.2 carrier assembly (22).
22
TI N
H
LA
ZX215-1006065
NY
2) Measurement of raised thickness Apply 3000 Kg load to the bearing and measure the value (H) of the raised part of the bearing.
SA
Load 3000Kg h
● Turn the hub 2-3 times before applying a pushing force. ● Do not use a spray gun to cushion the bearing. ● Do not push or strike the resin retainer. 3) Shim thickness calculation: C=H-h.
8-42
Shop Manual - June 2013
ZX215-1006066
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
4) Place the shims on the body and insert the dowel pin. Press the carrier assembly onto the dowel pin and tighten it with screw (21). Apply locking adhesive to the threads.
Tensiometer
Screw-locking adhesive: (Tonsan 1277)
A
Screw (21):
ZX215-1006067
RI C
539±28 N·m {55±2.9 kgf·m}
Tangential force: Max.294 N {30 kg} Maximum tangential force occurs when the rotating direction begins to change.
AM E
● Use a tensiometer to measure the tangential force of hub to motor rotation.
TI N
3. Assembly of No.2 planetary carrier assembly
LA
1) Assemble the No.2 planetary carrier assembly according to the following procedure.
NOTE: Replace the plates (20) and (16) with new parts.
18
19
15 16
17 20 21
23
22
ZX215-1006060
SA
NY
2) Assemble the bearing (18) and bearing (19) to the gear (17). Assemble the top and bottom plates (16) and (20), and place the gear assembly into the carrier assembly (22). 3) Tighten the screw (15). Screw (15): 539±28 N·m {55±2.9 kgf·m} ● Check the flexibility of gear (17) after assembling the planetary carrier assembly.
Shop Manual - June 2013
8-43
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
4. Thrust washer
13
14
Install the thrust washer (13). 5. No.2 sun gear
RI C
A
Install No.2 sun gear (14).
ZX215-1006059
6. No. 1 sun gear shaft
AM E
12
TI N
Install No.1 sun gear shaft (12).
LA
ZX215-1006058
7. No.1 planetary carrier assembly
NY
1) No. 1 planetary carrier assembly is assembled as the following.
9
7
5
4
10
8
SA
NOTE: Replace the thrust washers (7) and (11) with new parts. 2) Assemble the bearings (9) and (10) onto the gear (8). Assemble the top and bottom thrust washers (7) and (11). Place the gear assembly into the carrier assembly (6).
11
3) Fix the coverplate (5) to the carrier assembly (6) with screw (4).
8-44
Shop Manual - June 2013
6 ZX215-1006057
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
4) Install No.1 planetary carrier assembly (3).
A
3
8. Spacer
2
ZX215-1006055
LA
TI N
AM E
Install the spacer (2).
RI C
ZX215-1006056
9. Cover
NY
Use eyebolts to assemble the cover (1). Use a torque spanner to tighten the bolts. Bolts:
SA
73.4±3.63 N·m {7.5±0.4 kgf·m}
Torque wrench
10. Oil adding
Tighten the drain plug and add engine oil through the filler. ZX215-1006068
Final drive case: approx. 4.7 L ● Check the oil level after the final drive has been successfully installed to the chassis.
Shop Manual - June 2013
8-45
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.12 Swing Motor and Swing Drive AS - Remove and Install 8.12.1 Removal CAUTION
RI C
A
● Lower the work equipment to the ground. Stop the engine. Press the release button of the breather valve to release residual pressure in the hydraulic tank. Place the hydraulic lockout control in the LOCK position.
AM E
Release the residual pressure in the hydraulic circuit. Refer to “Residual Pressure in Hydraulic Circuit - Release” on page 6-40. 1. Disconnect the hoses (1) to (7). ● Between hydraulic tank and swing motor (port DR)
3
TI N
● Between central swivel joint and swing motor (port DR)
● Between swing motor and main valve (port M)
LA
● Between swing motor and main valve (port HA)
5
4
1
2
6
7
ZXT225-1106002
● Between swing motor and main valve (port HB)
NY
● Between swing motor and main valve Px port (port SH)
SA
● Between swing motor and solenoid valve block (port PG)
8 9
2. Remove the 11 fixing bolts (8). 3. Lift the swing motor and swing drive assembly (9) for disassembling. NOTE: Slowly lift the swing motor and swing drive assembly in order to avoid damaging the hoses and other parts. Swing motor and swing drive assembly: 260 kg 8-46
Shop Manual - June 2013
ZXT225-1106003
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.12.2 Installation ● Installation is performed in the reverse order of removal. Mounting bolts (swing motor and swing drive assembly): 490~608 N·m {50~62 kgf·m}
A
● Hydraulic oil adding
SA
NY
LA
TI N
For more information, see “Air in Each Component - Bleed” on page 6-46.
AM E
● Air bleeding
RI C
Add hydraulic oil through the filler opening to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again.
Shop Manual - June 2013
8-47
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.13 Swing Motor and Swing Drive AS - Disassemble and Assemble 8.13.1 Disassembly 1. Draining of oil Open the drain plug to drain the oil from the swing drive.
A
Swing drive: approx. 4.4 L
2) Unscrew the 14 bolts in order to remove the swing motor assembly (1).
3. No.1 sun gear
LA
TI N
Swing motor assembly: 70 kg
1
AM E
1) Place the swing motor and swing drive assembly on a suitable cribbing. Be careful not to damage the drive gear or let it contact the ground.
RI C
2. Swing motor assembly
ZX225-1006077
2
SA
NY
1) Remove No.1 sun gear (2).
ZX215-1006072
8-48
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
4. No.1 planetary carrier assembly
4
3
2) Disassemble the carrier assembly.
6
5
7
8
9
NY
LA
TI N
Cut the rivets on the shaft (8) to remove the shaft (8), and remove in turn the gear (6), bearing (9) and plate (7).
ZX215-1006073
AM E
RI C
A
1) Remove No.1 carrier assembly (3) and the plate (4).
5. Ring gear
ZX215-1006074
10
SA
Unscrew the mounting bolts to remove the ring gear (10).
ZX215-1006075
Shop Manual - June 2013
8-49
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
6. No. 2 sun gear
11
RI C
A
Remove No. 2 sun gear (11).
7. No.2 planetary carrier assembly 1) Remove No.2 carrier assembly (12).
AM E
ZX215-1006076
12
LA
TI N
2) Disassemble No. 2 carrier assembly as per the following procedure.
SA
NY
ZX215-1006077
8-50
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
3) Insert pin (13) and push the shaft (14) out of the carrier assembly (19). 19
NOTE: Pull out the pin (13) after removal of the shaft.
16
15
18 17
4) Remove the thrust washer (16), gear (17) and a second thrust washer (19).
14 13
A
5) Insert the pin (15) to remove the bearing (18) from the shaft. Remove the pin (15).
RI C
ZX215-1006078
8. Snap ring
AM E
20
NY
LA
TI N
Remove the snap ring (20).
ZX215-1006079
9. Disassembly of main shaft Press
21
22
SA
1) Place the shaft housing assembly on a press and push the shaft assembly (21) out of the shaft housing assembly (22).
ZX215-1006080
Shop Manual - June 2013
8-51
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
2) Disassemble the shaft assembly in the following procedure.
Press
Remove the bearing (23) from the shaft (24).
23
RI C
A
24
10. Bearing
AM E
ZX215-1006081
26
27
NY
LA
TI N
Remove the bearing (25) and the oil seal (26) from the housing (27).
SA
25
8-52
Shop Manual - June 2013
ZX215-1006082
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.13.2 Assembly NOTE: Clean all the parts and check for any contamination or damage. Apply engine oil to the sliding surface of the parts.
23
1. Bearing
2. Oil seal Press the oil seal (26) into the housing (27).
AM E
RI C
A
Press the bearing (23) into the housing (27).
27
ZX215-1006083
26
TI N
Oil seal installation surface:
27
LA
Gasket sealant (Loctite 515)
NY
ZX215-1006084
3. Housing assembly
SA
24
1) Position the plate (28) on the shaft (24). 2) Position the housing assembly (22) on the shaft (24). Press in the bearing. 22
28
Shop Manual - June 2013
ZX215-1006085
8-53
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
4. Bearing
22
25
Press in the bearing (25). ● When press fitting the bearing, press the bearing inner race and outer race simultaneously. Never press only the inner race.
RI C
A
● After assembling the bearing, check if the housing rotates freely.
5. No. 2 Planetary carrier assembly 1) Reassemble No. 2 carrier assembly according to the following procedure.
19
TI N
2) Assemble the plate (16) in the carrier assembly (19).
AM E
ZX215-1006086
LA
3) Assemble the gear (17) in the carrier assembly (19). Put the bearing (18) on the shaft (14). Slightly tap the pin (15) into the bore after alignment. Use a rubber hammer to tap the pin. Make sure that the pin (15) must not higher than the bearing (18).
SA
NY
4) Push the shaft assembly into the carrier assembly (19). Be careful not to damage the gear and the plate. Align the pin bore of the shaft with that of the carrier assembly, and install the pin (13). Carefully tap the pin with a rubber hammer during installation. NOTE: Installation of the shaft requires rotating the planetary gear. Be careful not to damage the thrust washer.
8-54
Shop Manual - June 2013
16
15
18 17 14 13
ZX215-1006078
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
6. Assemble in turn the snap ring (20), No.2 carrier assembly and No.2 sun gear (11).
No.2 planetary carrier 11
7. Installation of ring gear
ZX215-1006087
AM E
RI C
A
20
10
c
TI N
Apply sealant on the mating surface indicated by (C) and tighten it with screws. Never get the sealant onto the ring gear (10). Mating surface:
LA
Sealant (Loctite 515)
NY
ZX215-1006088
8. No. 1 planetary carrier assembly
SA
1) No. 1 carrier assembly is assembled as per the following procedure. 2) Install the plate (7) into the carrier assembly (5).
5
6
7
8
9
3) Install the gear (6) onto the plate after installing the bearing (9) into the gear. 4) Press the shaft (8) into the gear (6) and the carrier assembly (5). Rivet one end of the shaft.
ZX215-1006074
● Check if the gear rotates freely.
Shop Manual - June 2013
8-55
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
5) Install No. 1 carrier assembly (3) and the plate (4).
4
RI C
A
3
AM E
ZX215-1006073
2
9. No. 1 sun gear assembly
LA
TI N
Install No. 1 sun gear (2).
SA
NY
ZX215-1006072
8-56
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
10. Installation of swing motor assembly Apply sealant to the contact surfaces of the ring gear and the motor cover, and install the swing motor assembly. Contact surface: Sealant (Loctite 515)
A
Swing motor assembly: 55 kg
RI C
Mounting bolts (swing motor):
11. Lubricant adding
ZX215-1006089
LA
TI N
NOTE: The 14 bolt holes of the swing motor and swing drive assembly are distributed nonuniformly. The mating direction of each hole is fixed, as shown in the illustration on the right. The installation of swing motor requires proper alignment of the bolt holes in order to ensure the installation orientation.
AM E
156±5 N·m {16±0.5 kg}
NY
Screw on the drain plug and add lubricant through the filler to the specified level (the upper mark of oil stick).
SA
Swing drive: approx. 4 L
Shop Manual - June 2013
8-57
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.14 Idler AS - Disassemble and Assemble 8.14.1 Disassembly 7
8
6
13 12
2. Remove the float seals (3) from the support (2) and the idler (4). 3. Remove the O-ring (11). Remove the idler (4) from the shaft (5) and the support assembly (7).
5
RI C
4
3
1
2
ZX215-1006090
6
TI N
4. Remove the float seals (6) on the other side from the idler (4), shaft (5) and support assembly (7).
4
AM E
NOTE: The idler contains 80 ml oil, which should be drained completely before disassembling. Spread a cloth on the floor to prevent smearing the floor with oil.
9 11
10
A
1. Remove the dowel pin (1) and the support (2).
LA
5
6
NY
7
SA
ZX215-1006091
5. Remove the dowel pin (8) in order to remove the support (7) from the shaft (5). 6. Remove the bushings (9) and (10) from the idler (4).
9，10
5 4
7
8 ZX215-1006092
8-58
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.14.2 Assembly 1. Install the bushings (9) and (10) in the idler (4). 9
10
4
AM E
2. Assemble the O-ring. Install the support (7) to the shaft (5) with the dowel pin (8).
RI C
A
4
TI N
9，10
ZX215-1006093
5 4
7
8
LA
ZX215-1006092
NY
3. Install the float seals (6) to the idler (4), shaft (5) and support (7) assembly.
SA
● Float seals
6
Completely remove the grease from the contact surfaces (hatched area in the illustration on the right) of O-ring and float seal before installing the float seal. In addition, care must be taken to keep the contact surface of float seal free from dust.
Shop Manual - June 2013
ZX215-1006094
8-59
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
● After installation of the float seals, check that the sealing inclination should be less than 1 mm and the seal protrusion between 5 and 7 mm.
A
a
4. Install the shaft (5) and support (7) assembly to the idler (4).
SA
NY
LA
TI N
AM E
7
RI C
ZX215-1006095
8-60
Shop Manual - June 2013
5
4
ZX215-1006096
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
5. Install the float seal (3) to the idler (4) and support (2). 4
NOTE: Apply oil to the sliding surface of float seal. Care must be taken to keep the sliding surface from any contaminants or dust.
3 2
A
NOTE: Remove the oil and dust from the contact surfaces of the O-ring and float seal.
3
AM E
RI C
ZX215-1006097
LA
TI N
3
6. Install the O-ring. Install the support (2) with the dowel pin (1).
ZX215-1006098
7
8
6
NY
7. Add oil and screw on the plug.
13 12
10
5
SA
Oil: approx.
9 11
80 ml (No.18 hyperbola gear oil)
3
1
Plug:
205.8±49 N·m {21±5 kgf·m} 4
Shop Manual - June 2013
2
ZX215-1006090
8-61
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.15 Sprocket - Remove and Install 8.15.1 Removal 1. Remove the track assembly. Refer to “Track AS - Remove and Install” on page 8-63.
1
①
3. Remove the sprocket (1).
TI N
AM E
Sprocket: 58 kg
8.15.2 Installation
LA
● Installation is to be performed in the reverse order of removal. Threads (bolt - sprocket):
NY
Thread sealant (Tonsan 1277) Bolts (sprocket):
SA
339±20 N·m {35±2 kgf·m}
8-62
RI C
A
2. Swing the work equipment 90°and lift the chassis with the work equipment. Place a block between the track frame and the track shoe.
Shop Manual - June 2013
ZX215-1006099
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.16 Track AS - Remove and Install Special tools Part Name
Necessity Qty
M
Manual/electric hydraulic track removing/installing machine
●
1
A
Mark
WARNING
1
TI N
2. Lower the work equipment. Loosen the grease fitting (1) and release the track tension.
AM E
1. Choose a place that has enough space to spread the track. Park the machine when the master pin is between the idler and the carrier roller.
RI C
8.16.1 Removal
● The adjustment cylinder is under extremely high pressure. Never loosen the grease fitting by more than one turn.
LA
ZX215T-1006100
3. Pull out the master pin (2) with the tool (M).
SA
NY
2
M
ZX215-1006101
Shop Manual - June 2013
8-63
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
4. Remove the tool (M). Move the machine forward so that the temporary pin is in front of the idler. Place the block . 5. Remove the temporary pin and the dust seal. Move the machine backward to spread the track (3).
②
A
3
RI C
①
SA
NY
LA
TI N
AM E
ZX215-1006102
8-64
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.16.2 Installation ● Installation is to be performed in the reverse order of removal.
Corner
For more information, see “Track Tension Test and Adjust” on page 6-24.
R Corner
Track shoe bolts:
AM E
RI C
Seat surface in close contact
ZX215-1006103
TI N
2. Tighten the bolts of track shoe to the torque below.
Corner
R
1. Bring the R side of the track shoe nut (1) to the link seat surface. Both seat surfaces should be in close contact when assembling the track shoe.
R
A
● Installation procedure of track shoe bolts and nuts
NOTE: If the track shoe bolts are installed from the other side, the corner of nut will interfere with the link seat surface, causing the nut to raise and the bolt to loosen.
Track shoe nut (Square)
LA
750±30 N·m {77±3 kgf·m}
● Use the tool (M) to press the master pin. Make sure that the protrusion of master pin meets the size (a).
NY
Master pin protrusion (a): 2.5±1 mm
SA
● Before installing the dust seal, apply grease (No.2 lithium base) to its contact surface with the bushing.
a
ZX215-1006104
Shop Manual - June 2013
8-65
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.17 Swing Bearing AS - Remove and Install 8.17.1 Removal 1. Remove the swing platform assembly. For more information, see “Swing Platform AS - Remove and Install” on page 8-68.
AM E
RI C
A
2. Dismount the 36 bolts (1) to remove the swing bearing assembly.
2
1
TI N
3.
ZX215T-1006105
Hoist the swing bearing assembly (2).
2
SA
NY
LA
Swing bearing assembly: 314 kg
8-66
ZX215T-1006106
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.17.2 Installation ● Installation is to be performed in the reverse order of removal. Threads (bolt - swing bearing): Thread adhesive (Tonsun 1277) Mounting bolts (swing bearing):
RI C
A
Step 1: Use a pneumatic spanner to tighten the bolts.
Torque to: 549±59 N·m {56±6kgf·m} 1) When a torque spanner is used to tighten the bolts, tighten first the four corners and mark them.
AM E
Step 2:
TI N
2) Other bolts will be tightened clockwise or counterclockwise. After one bolt is tightened, tighten the next one on the diagonal position and make a mark.
LA
3) Tighten the rest bolts in this way.
NY
● Let the S mark in the soft zone of the inner race of the inner ring face the right side, as shown in the photo, and install the swing bearing to the track frame.
SA
● Apply grease to the inside of the gear ring of the swing bearing. NOTE: All gear teeth must be covered by grease . Inner race soft zone
Swing bearing: Grease(supramoly lithium base):15 L
ZX215T-1006107
Shop Manual - June 2013
8-67
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.18 Swing Platform AS - Remove and Install 8.18.1 Removal CAUTION
RI C
A
● Fully extend the arm and the bucket. Lower the work equipment to the ground and move the hydraulic lockout control lever to the LOCK position.
For more information, see “Work Equipment AS - Remove and Install” on page 8-105. 2. Remove the counterweight assembly.
TI N
For more information, see “Counterweight AS - Remove and Install” on page 8-113.
AM E
1. Disassemble the work equipment assembly.
3. Remove the four hoses (1) of boom cylinder.
1
ZX215T-1006108
LA
NOTE: Plug the hoses to prevent flow of oil.
SA
NY
4. Lift the boom cylinder assembly (2).
2 ZX215T-1006109
8-68
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
5. Remove the plate (3) and the pin (4). Lift the boom cylinder assembly (2) in order to remove it.
4
● Remove the boom cylinder assembly on the other side in the same way. Boom cylinder AS: 230 kg
ZX215T-1006110
5 6
TI N
NOTE: Removal of the swing platform requires removing other parts that interfere with the lifting of swing platform.
AM E
6. Remove the plate (5), air intake hose (6) and fan guard (7).
RI C
A
3
7 ZX215T-1006111
LA
7. Disconnect the six hoses above the swivel joint assembly.
NY
● Central swivel joint (port A) - Left travel control valve (port BTL)
SA
● Central swivel joint (port C) - Left travel control valve (port ATL) ● Central swivel joint (port F) - Solenoid valve ● Central swivel joint (port G) - Swing motor (port T) ● Central swivel joint (port D) - Right travel control valve (port ATR)
10 9 8
11 12 13 14
ZX215T-1006112
● Central swivel joint (port B) - Right travel control valve (port BTR) 8. Remove the bolt (14).
Shop Manual - June 2013
8-69
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
9. Unscrew the 32 swing platform mounting bolts in order to remove the swing platform assembly (15). Lift the swing platform assembly off the machine.
15
RI C
A
NOTE: Remove the front and rear mounting bolts of the platform. Use a lever block to adjust the swing platform so that the platform can reach a balance both longitudinally and laterally. Remove the last two bolts finally.
NOTICE
Swing platform assembly:
ZX215T-1006113
AM E
● Be careful not to impact the central swivel joint while removing the swing platform assembly.
Swing Platform Only (Ref.) 1,689 kg
TI N
Assembly
SA
NY
LA
8,427 kg
8-70
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.18.2 Installation ● Installation is to be performed in the reverse order of removal. Clamping screws (air intake hose): 5.4~6.4 N·m {0.55~0.65 kgf·m}
A
Mating surface (swing bearing):
RI C
Flat surface sealant (Tonsun 1596) Threads (bolt - swing platform):
Mounting bolts (swing platform): Step 1: Tighten the bolts with a pneumatic spanner. Step 2: tighten them again.
AM E
Thread adhesive: (Tonsun 1277)
TI N
490~608 N·m {50~62 kgf·m}
● Hydraulic oil adding
LA
Add through the filler opening the hydraulic oil to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again.
NY
● Air bleeding
SA
Bleed the air from the travel motor. For more information, see “Air in Each Component - Bleed” on page 6-46.
Shop Manual - June 2013
8-71
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.19 Swivel Joint AS - Remove and Install 8.19.1 Removal WARNING
A
● Release residual pressure in the hydraulic circuit before disconnecting the hydraulic hoses.
RI C
Refer to “Residual Pressure in Hydraulic Circuit - Release” on page 6-40.
1. Disconnect the six hoses from (1) to (6) on the central swivel joint of the travel motor.
TI N
1) Central swivel joint (port T) - Left travel motor (port T)
AM E
NOTE: Tag each line so as to ensure correction installation.
2) Central swivel joint (port T) - Right travel motor (port T)
4
5
6
LA
3) Central swivel joint (port B) - Left travel motor (port PA) 4) Central swivel joint (port D) - Right travel motor (port PB)
NY
5) Central swivel joint (port A) - Left travel motor (port PB)
SA
6) Central swivel joint (port C) - Right travel motor (port PA)
8-72
3
Shop Manual - June 2013
2 1
ZX215T-1006114
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
2. Disconnect the eight hoses from (7) to (14). 10
7) Central swivel joint (port F) - Left travel motor (port P)
9 13
8) Central swivel joint (port F) - Right travel motor (port P) 7 11
10) Central swivel joint (port F) - Solenoid valve
12
14
RI C
15
13) Central swivel joint (port D) - Right travel control valve (port ATR)
3. Remove the fixing bolt (15).
TI N
14) Central swivel joint (port B) - Right travel control valve (port BTR)
ZX215T-1006115
AM E
11) Central swivel joint (port C) - Left travel control valve (port ATL) 12) Central swivel joint (port A) - Left travel control valve (port BTL)
8
A
9) Central swivel joint (port G) - Swing motor (port T)
LA
4. Remove the four mounting bolts (16).
16 ZX215T-1006116
NY
5. Remove the six mounting bolts (17) from the transition plate. Remove the swivel joint assembly (18). 18
SA
Central swivel joint: 56 kg
Transition plate
17
Shop Manual - June 2013
16 ZX215-1006117
8-73
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.19.2 Installation ● Installation is to be performed in the reverse order of removal. NOTE: Install the central swivel joint facing the direction indicated in the illustration.
BD
Central swivel joint Sprocket
Add through the filler opening the hydraulic oil to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again.
Bleed the air from the travel motor.
SA
NY
LA
TI N
For more information, see “Air in Each Component - Bleed” on page 6-46.
AM E
● Air bleeding
AC
8-74
RI C
A
● Oil adding (hydraulic tank)
Shop Manual - June 2013
ZX215-1006118
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.20 Swivel Joint AS - Disassemble and Assemble 8.20.1 Disassembly 1. Remove the bolt (1) and the spring washer (2).
1 2
2. Remove the cover (3).
3
3. Remove the gasket (4), O-ring (5) and snap ring (6).
A
4
RI C
5
4. Remove the rotor (13) from the housing (9).
5. Remove the spacer (7) and the gasket (8) from the housing (9). 6. Remove the dust seal (12) from the swing shaft (13).
AM E
NOTE: Be careful not to damage the sliding surface of the seal of the rotor (13).
NY
LA
TI N
7. Remove the O-ring seal (11) and the seals (10) from the housing (9).
6 7 8
9
10
11 12
13
SA
ZX215-1006119
ZX215-1006120
Shop Manual - June 2013
8-75
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.20.2 Assembly 1. Install the dust seal (12) on the rotor (13). NOTE: Let the lip face the housing while installing the dust seal.
Dust seal
2. Install the six seals (10) in the housing (9). Lip
4. Use a rubber hammer to tap the housing (9) in order to match the rotor (13) properly.
RI C
ZX215-1006121
TI N
5. Install the spacer (7) and gasket (8) in the housing (9).
Body
AM E
NOTE: Since the clearance between the housing (9) and the rotor (13) is approximately 0.1 mm, install the housing (9) on the rotor (13) slowly and vertically. Be careful not to damage the seals (10) and the O-ring seal (11).
A
3. Fix the rotor (13) on a work bench. Install the housing (9) on the rotor (13).
6. Install the gasket (4), O-ring seal (5) and snap ring (6) on the rotor (13).
LA
7. Install the cover (3). Tighten the bolts (1) and the spring washer (2).
SA
NY
Fixing bolts: 49 N·m{5 kgf·m}
8-76
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.21 Hydraulic Tank AS - Remove and Install 8.21.1 Removal 1. Drain the hydraulic oil into a suitable container for storage or disposal.
1
Hydraulic oil: approx. 225 L
2
5
3
RI C
3. Remove the engine hood (1), cover (2) and control valve cover (3).
ZX215T-1006122
6
7
TI N
AM E
4. Remove the cover mounting frame (4) and the screen (5).
5. Remove the screen (6) and the partition frame mounting bolt (7) on the hydraulic tank side.
4
A
2. Open the engine hood.
LA
6. Remove the screw (8) and the fuel control motor (9).
9
8
NY
ZX215T-1006123
SA
7. Remove the two oil return hoses (10) from the hydraulic tank. 10
ZX215T-1006124
Shop Manual - June 2013
8-77
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8. Disconnect the seven hoses. ● (11): Oil return - pilot T block ● (12): Oil return - main pump 17
● (13): Oil return D2 - main valve ● (14): Sensor - temperature
18
● (16): Oil return D1/D3 - main valve
13 16
● (17): Oil return - swing motor
● Disconnect the oil inlet hose (18) from the hydraulic tank after disconnection of the oil inlet tube from the pump. ● Attach each hose with an identification tag.
14
ZX215T-1006125
19
LA
9. Remove the hose clamp (19).
TI N
● Use a sleeve nut to prevent the fitting and the cone seal from damage.
12
AM E
NOTE:
11
A
15
RI C
● (15): Oil return - solenoid valve
ZXT225-1106008
NY
10. Lift the hydraulic tank assembly and remove the six bolts (20).
SA
11. Lift off the hydraulic tank assembly for disassembling.
20
Hydraulic tank assembly: 130 kg
ZX215T-1006127
8-78
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.21.2 Installation ● Installation is to be performed in the reverse order of removal.
Screw
Drain plug (hydraulic tank): 58.8~78.5 N·m {6.0~8.0 kgf·m} NOTE: After tightening the hose clamping screw, check that the screw should be in the range indicated in the illustration.
RI C
A
Up Down
Screw (hose clamp):
● Install the hose clamp and tighten the screw according to the illustration on the right. Bolt:
● Oil adding (hydraulic tank)
Pipe
TI N
245.2~308.9 N·m {25~31.5 kgf·m}
AM E
8.8±0.5 N·m {0.9±0.05 kgf·m}
LA
Add hydraulic oil through the filler opening to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again.
Clamp
ZX215-1006128
Hose
Bulge ZX215-1006129
NY
● Air bleeding
SA
For more information, see “Air in Each Component - Bleed” on page 6-46.
Shop Manual - June 2013
8-79
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.22 Control Valve AS - Remove and Install 8.22.1 Removal
● Lower the work equipment to the ground. Stop the engine. Press the release button of the breather valve to release residual pressure in the hydraulic tank. Place the hydraulic lockout control in the LOCK position.
RI C
1
AM E
NOTE: Tag each line so as to ensure correction installation.
1. Lift the hood (1).
A
WARNING
2
ZXT225-1106009
TI N
2. Remove the cover (2) above the control valve.
LA
3. Remove the engine silencing hood (3).
3
NY
ZXT225-1106010
SA
4. Remove the baffle (4) to (9) of the pressure transducer and tag them. (4): XAK Bucket DIG (5): XBb1 Boom DOWN
4
(6): XAtL Travel LEFT
5
7 8
(7): XBa1 Arm IN
6
9
(8): XBs Swing RIGHT (9): XAtr Travel RIGHT
8-80
ZXT225-1106011
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
5. Disconnect the pilot hoses (10) to (18) and tag them properly.
10
11
12
13
14
(10): XBtr Travel RIGHT (11): XAs Swing LEFT 18
(12): PSP Swing priority 15
16
(14): XBp2 Bucket confluence
17
RI C
(15): XBtL Travel LEFT
A
(13): XAa1 Arm OUT
(16): XAb1 Boom UP
(18): XAa2 Arm OUT
21 19
20
ZXT225-1106013
NY
LA
TI N
6. Remove the port (19) (accumulator to solenoid valve), port (10) (pilot filter to accumulator). Remove hose clip (21) of the central swivel joint.
AM E
(17): XBK Bucket DIG
ZXT225-1106012
SA
7. Remove bucket hoses (22) and (23) and seal the ports. 8. Remove arm hoses (24) and (25) and seal the ports. 9. Remove boom hoses (26) and (27) and seal the ports.
22
24
25
23
26 27
Shop Manual - June 2013
ZXT225-1106014
8-81
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
10. Remove central swivel joint hoses (28), (29), (30) and (31). Remove travel speed switching hose (32) and seal the ports.
32
31
A
28
30
29
AM E
11. Remove swing motor hoses (33) and (34). Remove swing motor oil complement hose (35). Seal the ports properly.
RI C
ZXT225-1106015
33
34
ZXT225-1106016
LA
TI N
35
12. Remove pipe (36) (main valve to radiator).
SA
NY
36
ZXT225-1106017
8-82
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
13. Remove pipe (37) (main valve to return oil tank). Seal the ports properly.
AM E
ZXT225-1106018
38
39 ZXT225-1106019
LA
TI N
14. Remove hydraulic pump hoses (38) and (39).
RI C
A
37
15. Remove hoses (40) to (44) on the solenoid valve and tag them properly.
NY
(40): PPC lockout valve
SA
(41): Main valve PnA2
(42): Main valve XBP2 (43): Main valve PSP (44): Travel PT port
40 41
42
43
44 WXT215-1208001G
Shop Manual - June 2013
8-83
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
16. Remove the fixing bolts (45). Lift the control valve assembly (46) for disassembling. Control valve assembly: 220 kg
45
45
RI C
A
46
8.22.2 Installation
● Oil adding (hydraulic tank)
TI N
● Installation is to be performed in the reverse order of removal.
AM E
ZXT225-1106021
LA
Add hydraulic oil through the filler opening to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again. ● Air bleeding
NY
Bleed the air from the circuit between the valve and the hydraulic cylinder.
SA
For more information, see “Air in Each Component - Bleed” on page 6-46.
8-84
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.23 Hydraulic Pump AS - Remove and Install 8.23.1 Removal WARNING
RI C
A
● Lower the work equipment to the ground and stop the engine. Press the release button of the breather valve to release residual pressure in the hydraulic tank.
NOTE: Tag each line so as to ensure correction installation.
TI N
1. Remove the oil inlet filter element from the hydraulic tank and stop oil outflow with an oil stopper.
AM E
● Disconnect the cable from the negative (-) post of the battery before performing the job.
NOTE: If no oil stopper is used, remove the drain plug and drain the oil from the hydraulic tank and from circuits.
LA
Oil stopper
Hydraulic tank: Approx. 225 L
ZX215-1006144
SA
NY
2. Lift the hood (1).
1
ZX215T-1006145
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Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
A
3. Remove the pin (2) and the bolts (3). Lift the engine hood in order to remove it.
ZX215T-1006146
4
3
LA
TI N
AM E
4. Remove the right upper cover (4).
RI C
2
ZX215T-1006147
SA
NY
5. Disconnect the hose (5) supplying oil to the lower proportional valve and the hose (6) delivering oil from the pilot pump.
5
6 ZX215T-1006148
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Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
RI C
7
A
6. Disconnect the shutdown wire (7).
TI N
8. Remove the hydraulic pump cover (9).
AM E
7. Remove the right door (8).
ZX215T-1006149
8 9
LA
ZX215T-1006150
9. Disconnect the oil drain hose (10) and seal the openings properly.
NY
10
SA
10. Disconnect the high-pressure hoses (11) and (12) connecting to the control valve, and seal the openings properly. 11. Disconnect the harness (13) of the pressure transducer. 12. Disconnect the pilot pump oil inlet hose (14) and seal the openings properly.
12 11 13
14
13. Disconnect the pilot pump oil inlet tube (15) and seal the openings properly.
Shop Manual - June 2013
15
ZX215T-1006151
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Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
16
18
RI C
A
14. Disconnect the solenoid valve harnesses (16) and (17). Remove the cable straps (18) and (19).
19
17
15. Remove the four bolts (20) of the hydraulic pump. Lift the hydraulic pump assembly (21) to remove it.
21
SA
NY
LA
TI N
Hydraulic pump assembly: 112 kg
AM E
ZX215T-1006152
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Shop Manual - June 2013
20
ZX215T-1006153
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.23.2 Installation ● Installation is to be performed in the reverse order of removal.
Screw
NOTE: After tightening the hose clamping screw, check that the screw should be in the range indicated in the illustration. Up Down
A
Screw (hose clamp):
Mating surface (hydraulic pump housing):
AM E
● Install the hose clamp and tighten the screw according to the illustration on the right.
RI C
8.8±0.5 N·m {0.9±0.05 kgf·m}
Pipe
Clamp
ZX215-1006128
Hose
Bulge ZX215-1006129
LA
TI N
Gasket sealant: (Loctite 515)
● Oil adding (hydraulic tank)
NY
Add hydraulic oil through the filler opening to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again.
SA
Hydraulic tank: approx. 225 L ● Air bleeding
For more information, see “Air in Each Component - Bleed” on page 6-46.
Shop Manual - June 2013
8-89
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.24 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install 8.24.1 Removal 1. Remove the hydraulic pump assembly (1). For more information, see “Hydraulic Pump AS - Remove and Install” on page 8-85.
1 2
2. Remove the screw (2). Remove the bearing cover (3).
RI C
A
3 4
3. Pry the oil seal (4) out with a screwdriver.
AM E
NOTE: Be careful not to damage the shaft while prying the oil seal.
TI N
8.24.2 Installation
ZX215-1006154
● Installation is to be performed in the reverse order of removal.
4
LA
Seal lip:
Grease (No.1 Calcium base grease) Seal circumference:
NY
Grease (No.1 Calcium base grease)
SA
● Apply a thin layer of grease to the oil seal circumference.
8-90
ZX215-1006155
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.25 Pilot Valve AS (Work Equipment) - Disassemble and Assemble NOTE: This section discusses only the precautions when reassembling the work equipment pilot valve assembly. 8 2
3
4
5
6
7
10
8.25.1 Assembly ● Reassembly of the work equipment pilot valve assembly
TI N
1. Install the plate (9) in the valve body (8) with O-ring seal. Tighten the socket bolt (10).
LA
Socket bolt:
ZX215T-1006156
AM E
RI C
A
1
9
25~33 N·m {2.55~3.36 kgf·m}
Grease (No.1 Calcium base grease) U-joint moving surface: Grease (No.1 Calcium base grease) Threads in valve body: Thread adhesive (Tonsun 1277)
NY
2. Insert the spring (7) into the spool hole in the valve body (8). Put the spool (6) in the spring. Install the plunger (5) on the spool. Push the plug (5) to the spool hole.
Plug (5) circumference:
SA
3. Install the plate (4) on the plunger (5). Tighten the U-joint (3). 4. Install the plate (2). Align the position of the plate (2) and tighten the nut (1). Nut: 98~133 N·m {10~13.5 kgf·m} NOTE: Location of each oil port is stamped on the bottom of valve body.
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Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
● A p p l y t h e t h r e a d a d h e s i v e ( To n sun 1277) to two points on the inner threads. The amount of application is approximately 0.02 g.
5~7 mm
U-joint (3): 98~133 N·m {10~13.5 kgf·m}
A
NOTE: Tightening is to be made to the specified torque. Contact surface between plunger (5) and plate (2):
RI C
ZX215-1006157
SA
NY
LA
TI N
AM E
Grease 0.3~0.8 ml (No.1 Calcium base grease)
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Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.26 Pilot Valve AS (Travel) - Disassemble and Assemble NOTE: This section discusses only the precautions when reassembling the travel pilot valve assembly.
9
8
7
6
AM E
RI C
A
Plunger
4
3
2
1
5
TI N
ZX215T-1006158
8.26.1 Assembly
LA
● Reassembly of the pedal pilot valve assembly
1. Install the spring (8) into the spool installation hole in the body assembly (9). Install the spool (7). Place the cover assembly (6) on the spool and press the cover assembly (6) with a hand. 2. Install the cover (4) after aligning the holes. Tighten the socket bolts (1).
NY
Bolt (socket): 98~114 N·m {10~11.6 kgf·m}
SA
3. Install the dust ring (3) on the plunger. Install the cover (2) and fix the cover (2) with the camshaft (5). Contact surface between plunger and dust ring (5): Grease (No.1 Calcium base grease)
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Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.27 Hydraulic Cylinder AS - Disassemble and Assemble Special tools Application
Tool Shape
Necessity
Quantity
■
1
RI C
A
Pulling out/pushing in the bushing
TI N
O-ring seal correction
SA
NY
Inserting the piston
8-94
1
■
1
■
1
■
1
Correcting tool
LA
Inserting tool
Inserting the cylinder head
■
AM E
Press fitting the dust ring
Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.27.1 Disassembly 1. Drain the oil and remove the tubing. 2. Fix the cylinder.
A
● Fix the cylinder in a vertical or level manner. A vertically fixed cylinder can be disassembled and assembled easily.
AM E
● Remove the tubing in case of tubing interference while fixing the cylinder.
RI C
● The pin bore in the head end can be used for fixing of the cylinder. The pin roll can prevent the cylinder from turning.
LA
TI N
Fix the cylinder
NY
ZX215-1006164
3. Removal of cylinder head
SA
Approx 1.5m
● Unscrew the bolts with Allen Wrench. ● Using an extension rod, as shown in the illustration on the right, will make the work easy.
ZX215-1006165
Shop Manual - June 2013
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Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
4. Pulling out the piston rod ● Be sure to have removed the tubing cover. ● Prepare a suitable container to collect oil coming out of the oil port.
1
● After pulling out the piston rod to its limit, slowly loosen the cylinder head and pull it out.
2
Fixing
5
SA
NY
LA
TI N
● Use pin bore on the rod end or the flat part of the ear to prevent turning of the piston rod.
ZX215-1006166
AM E
5. Fixing the piston rod
RI C
● Remove the piston rod (1) with the cylinder head (2) and place them on a wooden sleeper.
A
Sleeper
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Shop Manual - June 2013
ZX215-1006167
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
6. Remove of the piston nut (5) Drill bit
1) Remove the fixing screw (3) from the piston nut (5).
3
A
NOTE: Around the fixing screw there are two points that have been punched against loosening. After removing the riveted part with a hand drill, loosen and remove the fixing screw (3). 2) Remove the steel ball (4).
RI C
4
3) Remove the piston nut (5).
5
AM E
NOTE: The piston nut (5) is very tight. To loosen the piston nut (5), prepare a hydraulic jack or a spanner powered by hydraulic cylinder. An extension rod should be ready when removing the piston nut (5) manually.
ZX215-1006168
TI N
Hydraulic jack Hydraulic cylinder
LA
ZX215-1006169
7. Removal of piston assembly
2
6
7
SA
NY
● Remove in turn the piston (7), buffer sleeve (6) and cylinder head (2).
ZX215-1006170
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Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8. Removal of the buffer sleeve (8) on the bottom end
Thread
1) Remove first the piston nut (5). Piston rod
9
3) Slide the buffer sleeve (8) toward the piston threads in order to remove the two-piece stopper ring.
RI C AM E
TI N
9. Removal of piston seal 1) The slide ring (12) and the guard ring (13) can be simply removed with hands.
LA
2) The seal (14) can be removed with a hammer and a flat-head screwdriver.
11 (2 pcs)
ZX215-1006171
4) Remove the buffer sleeve (8). 5) There is an opening in the buffer seal (10). Take advantage of this opening to remove the buffer seal (10).
8
10 one gap
A
2) Use a tool like rubber hammer to tap the piston nut (5) slightly for removal while keeping the piston rod and the buffer sleeve (8) intact. Remove the elastic ring (9).
Screwdriver 12
14 Piston
Bench clamp
3) Remove the O-ring seal (15) with a pry bar.
NY
15
13
ZX215-1006172
SA
NOTE: The removed seals should not be reused.
10. Removal of buffer ring (16) NOTE: The buffer ring (16) is installed in the inner groove in the cylinder head. Use a tool with sharp end to pry it out and remove it with a scraper.
18
17
16
19
20
ZX215-1006173
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Shop Manual - June 2013
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
11. Removal of the U-ring (17) and the dust ring (18) Press
1) Remove the U-ring (17) with a tool such as screwdriver. Cushion
2) Pierce a tool (such as a screwdriver) into the dust ring (18) and hammer the screwdriver to remove the dust ring (18). NOTE: The removed seals should not be reused.
RI C
Support
2) Push the bushing (19) out with the help of clamps and press. 13. Removal of bushing (21)
ZX215-1006174
AM E
12. Removal of bushing (19) 1) Remove the elastic ring (20) from the cylinder head (2) with a screwdriver.
A
21
TI N
1) Remove the dust ring (22) on the side of cylinder barrel and piston rod with a tool such as screwdriver.
SA
NY
LA
2) Remove the bushing (21) with the help of a suitable cushion block.
Shop Manual - June 2013
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Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.27.2 Assembly 1. Installation of bushing (21) 1) Use a mounting tool to press the bushing (21) into the bushing (lubricated with hydraulic oil) on the side of piston rod and cylinder barrel.
Press Mounting tool 21
2) Install the dust ring (22) with the help of a suitable cushion block.
Cushion
Piston rod
21
RI C
A
22
2. Assembly of cylinder head (2) 1) Use the press to push in the bushing (19).
Hydraulic press
2
Tool
TI N
NOTE: Apply hydraulic oil to the inside of cylinder head in advance. Make sure that the bushing (19) pushed in is free from a raised shoulder.
AM E
ZX215-1006175
19
Pressure surface
LA
2) Use the press to push in dust ring (18).
ZX215-1006176
Tool
SA
NOTE:
NY
3) Install the guard ring and the U-ring (17) sequentially in the U-groove.
● Install the U-ring (17) in correct direction. Make sure that the U-ring is intact before installation.
18 U-groove
Press in
● Inverse installation will cause leak of oil. ● Make sure that the U-ring is free from any corrugation or permanent deformation after installation.
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ZX215-1006177
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
4) Installation of buffer ring (16) NOTE: Make sure that the seal is installed in correct direction. Inverse installation can cause high pressure between the buffer ring (16) and the U-ring (17), which may lead to deformation or breakage of oil cylinder.
A
5) Install the elastic ring (20) to prevent the fall of the bushing (19).
RI C
3. Assembling the piston assembly 1) Installation of seal (14).
2) Correction of seal (14)
AM E
18
17
20
19
Press Block
Press
Tool 13
NY
LA
NOTE: Install the seal (14) and the guard ring (13) on the other side. In order to prevent the expansion of the seal (14), a corrector must be used to correct the seal (14) which has been stretched during installation. The piston rod may not be able to go in the cylinder barrel if the seal (14) is not corrected timely.
16
ZX215-1006173
TI N
NOTE: Install first the O-ring seal and the one-side guard ring (13) on the piston. Place the piston on the press. As shown in the illustration on the right, the seal (14) is installed with the tools indicated.
Tool
3) Installation of slide ring (12)
Corrector
Piston
SA
NOTE: Slightly open the slide ring (12) and install it axially. Excessive opening of the slide ring (12) can fail installation.
12 14 13
O-ring
ZX215-1006179
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Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
4. Assembling the piston rod assembly 1) Fix the piston rod (1).
2
Assembly tool
2) Install the cylinder (2) on the piston rod. NOTE: Make sure that the dust ring lip or the U-ring lip is not stopped by the shoulder of any part. Install the cylinder head and the piston rod with the tools.
RI C
TI N
5) Install the buffer sleeve (8) according to the indication in the illustration on the right.
ZX215-1006180
AM E
4) Let the notched side of the buffer seal (10) face the piston while installing the buffer seal (10) in the groove.
A
1
3) If the bottom side of cylinder contains a buffer (not for bucket cylinder), install the buffer bearing and the buffer seal in the following order.
Gap facing thread direction Thread
6) Install the stopper ring in the groove. Install the elastic ring after the buffer sleeve (8) is pushed to the bottom. A rubber hammer should be used for the tapping job in order to avoid damaging the piston rod and the buffer bearing.
LA
Piston rod
9
SA
NY
7) If the head side of cylinder contains a buffer, install the buffer sleeve (6) and the buffer seal (23) according to the following order. 8) The piston nut must be installed after installation of the buffer bearing. 9) The buffer seal (23) must be installed in the groove, with its notches facing the piston.
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10 One gap
8 Head end buffer
11 (2 pcs) ZX215-1006181
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
10) The buffer sleeve (6) must be installed according to the illustration on the right.
6
23
5
11) Tighten the piston nut (5). Piston nut (arm): 9600 N·m {979.6 kgf·m} Piston nut (boom and bucket):
A
6200 N·m {632.6 kgf·m}
Gap facing piston side
NOTE:
TI N
● Thoroughly clean and grease (with banana oil) the threaded portions of the piston, nuts and piston rod before tightening the nuts.
ZX215-1006182
AM E
● Insufficient tightening can cause oil leakage, loose nut and thread breakage. In addition, excessive tightening can cause expansion of the buffer shaft on the extending side or deformation of piston on the contact side.
RI C
Rod end buffer
LA
12) Treatment of the piston against loosening
NY
NOTE: After the piston nut (5) is tightened, put in the steel ball (4), tighten the setscrew (3) and punch to rivet the two peripheral points.
Rivet
Punch
Setscrew (3):
SA
66.9 N·m {6.8 kgf·m}
3 4
ZX215-1006183
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Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
5. Install the piston into the cylinder barrel
Tool Nylon sleeve (2 pcs type)
1) Fix the barrel in a vertical or level manner. 2) Install the piston rod into the cylinder barrel.
(Spread the gaps by 180°)
NOTE:
RI C
A
● If fixed in a vertical manner, the piston rod falls into the barrel under its gravity.
ZX215-1006184
AM E
● Make sure that the slide ring does not fall while the piston is inserted into the barrel.
TI N
6. Tightening of cylinder head Tighten the cylinder head according to the sequence shown in the illustration on the right.
4
5
6
11 10
3 2
7 Tightening sequence
SA 8-104
9
12
NY
7. Install the tubing.
LA
Bolt: 267 N·m {27.2 kgf·m}
1
8
Shop Manual - June 2013
ZX215-1006185
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.28 Work Equipment AS - Remove and Install 8.28.1 Removal WARNING
RI C
A
● Fully extend the arm and the bucket. Lower the work equipment to the ground. Move the hydraulic lockout control to the LOCK position.
See “Residual Pressure in Hydraulic Circuit Release” on page 6-40.
AM E
● Release residual pressure in the hydraulic circuit.
5
1
1. Disconnect the grease hose (1).
TI N
2. Lift the boom cylinder assembly (2). Remove the lock bolt (3).
3
2
4
3. Remove the plate (4) and then the pin (5).
NOTE: There are shims installed. Count the shims and check the thickness. Place the shims in a safe place.
LA
ZX215T-1006186
4. Start the engine and retract the piston rod.
SA
NY
NOTE: Secure the piston rod with a wire rope in order to prevent the piston from slipping out. Put the cylinder on a bench or support. Remove the grease fitting on the bottom side in the later case. Remove the other boom cylinder in the same way.
5. Remove the two hoses (6) of bucket cylinder and the those (7) of the arm cylinder.
6
8
NOTE: Cork the hoses to prevent outflow of oil. Secure the hoses to the valve side.
10
9
7
ZXT225-1106028
6. Remove the inter-connector (8) used for work lamp.
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Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
7. Lift the work equipment and remove the plate (9). Remove the pin (10) from the bottom. NOTE: There are shims installed. Count the shims and mark their locations.
SA
NY
LA
TI N
Work equipment assembly: 3451 kg
11
AM E
8. Lift and disassemble the work equipment assembly.
8-106
ZX215T-1006188
RI C
9
A
10
Shop Manual - June 2013
ZX215T-1006189
Disassembly and Assembly
SY195/205/215/225C9 Crawler Hydraulic Excavator
8.28.2 Installation CAUTION ● Do not put your finger in the pin bore while aligning the pin bore.
A
● Installation is to be performed in the reverse order of removal.
RI C
NOTE: A clearance (a: 0.5~1.5 mm) shall be left between the plate and the nut when tightening the locknut.
Grease (supramoly lithium base)
AM E
Greasing after assembling the pin:
a
TI N
NOTE: Adjust the shim thickness in order to have a desired clearance (a: 0.5
